Sharif Digital Repository

While it is well recognized that microstructure controls the physical and mechanical properties of a material, the complexity of the microstructure often makes it difficult to be simulated by analytical or numerical techniques. In this paper we present a suitable approach to compute microstructures within a casting using the finite element technique. This technique allows implementing microstructure data from experiments and equations that describe microstructure as function of local solidification parameters. The comparison of this model's predictions with the ones in the literature and also experimental measurements of secondary dendrite arm spacing, average length and diameter of silicon... 

A three phase electromagnetic stirrer was used to agitate aluminum A356 slurry and a dry and oxygen free argon gas was introduced in to the slurry by a porous graphite core at a same time. The prepared semi-solid slurry was then transferred into a metallic mold and was compacted by a drop weight. Results demonstrated a favorable increase in shape factor, decrease in aspect ratio and average diameter size at different intensities of stirring. The intensity of stirring was changed by altering the current passed through the magnetic coil and also bubbling intensity via the porous graphite diffuser. Different time intervals for electromagnetic stirring and gas induction were applied. Agitating... 

This article examines the Weibull statistical analysis that was used for investigating the effect of melt filtration on tensile properties and defects formed inside the casting. Forming and entrapping of double oxide films have been explained by using the context of critical velocity of melt in the runner. SutCast software results were used to examine the amounts of the velocity of melt as such. SEM/EDX analysis is used to observe the presence of double oxide films in the fracture surfaces of the tensile specimens. The article goes on to propose that castings made with foam filters with smaller pores show higher mechanical properties and reliability due to higher Weibull modulus and fewer... 

The cast-decant-cast is a new method for the preparation of the functionally graded components that has been developed in recent years. The functionally graded cylindrical shape component with a radial gradient, e.g. the first alloy (A390) with high wear resistance on the surface of the piece and toughness and the second alloy (A356) of low machining costs in the core of the piece can be produced via this melt process. The effect of the second alloy superheat at temperatures of 750, 820 and 860 °C as well as the effect of the first alloy solidified layer at 25, 35 and 45 s decanting time on achieving the perfect interface between the two alloys was investigated. The characterization of the... 

In this work, effective parameters of SIMA process to obtain non dendritic microstructure in A356 alloy were investigated. In addition, the effect of SIMA process on the evolution of morphology of silicon and intermetallic phases in this alloy was studied. Microstructure images obtained from optical microscopy and SEM observation showed that increase in plastic work up to 40% and then holding of samples in the semi solid state at temperature of 580°C, causes that primary dendritic structure changes to non dendritic, fine and globular structure, but optimum reheating time completely depended on initial thickness of samples. If all parameters of SIMA process are the same, the grain boundaries... 

A simple method for estimating the apparent viscosity of semi-solid alloys was investigated. A drop weight of 50Kg and backward extrusion equipments were used to test the deformation. Backward extrusion was employed in a closed die system due to the very little separation of liquid from solid phases compared with other methods at very high deformation rate. The half of the calculated impact velocity, 700mm/s was considered as an average velocity for deformation during the test, since the slop of the velocity changes against time is constant in the middle stage of the deformation. The initial height of the sample and the thickness of the residual compressed solid at the bottom of the cup were... 

Computer base and simulation technique have been applied for modeling the semi-solid die filling and part of the solidification process of aluminum A356 alloy. A fairly simple one-phase rheological model has been implemented into a fluid flow finite element software Procast, to solve the partial differential equations. This model is purely viscous nature and is implemented in the power law cut-off model of Procast. The constitutive parameters of this model were determined for a rheocast A356 alloy. Using these parameters and comparing the simulation results with experimental data showed good correlation with the model prediction. The designed die for rheocasting was applied for the... 

Friction Stir Welding (FSW) is a novel solid state welding process for joining materials. In this process a high speed tool is introduced into the weld seam and due to localized frictional heat, plastic deformation and transverse movement along the weld seam, joining is accomplished. In this study aluminum matrix composite A356 + 15%SiCp is chosen for friction stir welding. Fragmentation of SiC particles and silicon needles existing in eutectic phase as well as their homogenous distribution as a result of stirring with high plastic strains, improve mechanical properties such as modulus of elasticity, yield and ultimate strength, elongation and hardness in the weld zone compared to that of... 

The flow behavior of a semi-solid A356 alloy at high solid fraction was studied. The mushy zone was considered as an effective two-phase, so that the solid continuum can be compressible porous media, and the liquid phase interaction with the solid skeleton was of Darcy type. The semi-solid flow through the upsetting test was modeled in ABAQUS finite element method software. The Gurson yield criterion has been developed for the modeling process of the flow behavior of solid porous medium. Specimens were globulized by a thermomechanical process and then were tested for various percentages of upsetting. The distribution of solid fraction along the radius of the specimens at different height... 

In this study, in order to compare effect of unidirectional compression and rolling on final microstructure of strain induced melt activated (SIMA) A356 aluminum alloy, rectangular samples with dimensions of 3cm×5cm in area and 1cm in thickness and cylindrical specimens with 2.5cm in diameter and 1cm in length, have been prepared for rolling and compressing processes, respectively. Then, these samples were plastically deformed at a same strain in ambient temperature. Afterward, the strained samples were cut into equal quarters. In the next stage, to produce globular microstructure, these specimens were partially remelted in 580°C for different times. Results obtained from light microscopy...