Cast aluminum alloys physical properties

Kaufman, J. G. 2004, 2009. Aluminum Alloy Database. Norwich, NY Knovel an electronic book on Knovel. Originally published in 2004 and updated in 2009. Contains a comprehensive summary of physical, mechanical, and chemical properties of both wrought and cast aluminum alloys. It has interactive searchable and sortable tables. 

Calcium—Silicon. Calcium—silicon and calcium—barium—siUcon are made in the submerged-arc electric furnace by carbon reduction of lime, sihca rock, and barites. Commercial calcium—silicon contains 28—32% calcium, 60—65% siUcon, and 3% iron (max). Barium-bearing alloys contains 16—20% calcium, 9—12% barium, and 53—59% sihcon. Calcium can also be added as an ahoy containing 10—13% calcium, 14—18% barium, 19—21% aluminum, and 38—40% shicon These ahoys are used to deoxidize and degasify steel. They produce complex calcium shicate inclusions that are minimally harm fill to physical properties and prevent the formation of alumina-type inclusions, a principal source of fatigue failure in highly stressed ahoy steels. As a sulfide former, they promote random distribution of sulfides, thereby minimizing chain-type inclusions. In cast iron, they are used as an inoculant. 

The usual alloying additions to aluminum in order to improve physical properties include Cu, Si, Mg, Zn, and Mn. Of these, manganese may actually improve the corrosion resistance of wrought and cast alloys. One reason is that the compound MnAle forms and takes iron into solid solution. The compound (MnFe)Alg settles to the bottom of the melt, in this way reducing the harmful influence on corrosion of small quantities of alloyed iron present as an impurity [27]. No such incorporation occurs in the case of cobalt, copper, and nickel, so that manganese additions would not be expected to counteract the harmful effects of these elements on corrosion behavior. 

The properties of aluminum alloys (mechanical, physical, and chemical) depend on alloy composition and microstructure as determined by casting conditions and thermomechanical processing. While certain metals alloy with Al rather readily [9], comparatively few have sufficient solubility to serve as major alloying elements. Of the commonly used alloying elements, magnesium, zinc, copper, and silicon have significant solubility, while a number of additional elements (with less that 1% total solubility) are also used to confer important improvements to alloy properties. Such elements include manganese, chromium, zirconium, titanium, and scandium [2,10]. 

The metal casting industry conventionally divides casting products into ferrous and nonferrous metals, in particular, iron-based, steel-based, aluminum-based, and copper-based castings. The other castings of low fractions include magnesium, lead, zinc, and their alloys. In the U.S., the foundry industry currently produces 11 million tons of metal product per year, with a shipment value of 19 billion. Of them, iron and steel accounted for 84% of metals cast.5 The remaining 15% of foundry operations are concerned with aluminum, copper, zinc, and lead production. Table 4.2 summarizes critical physical and thermal properties of aluminum, iron/steel, and cast iron. 

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