Abstract:The microstructure and tensile properties were investigated in a thick-walled section (approximately 45 mm×43 mm) of a rheocast component produced by the RheoMetal^TM process. Due to the long solidification period of such components, it is expected that the Al-Si eutectic formed will be coarse. Therefore, sodium (Na) was used as a modifying agent to reduce the coarseness of the eutectic. Tensile test bars were machined from three different sets of materials: 1) non-modified melt, 2) modified melt cast directly after Na addition, and 3) modified melt cast 30 min after Na addition. The alloy used was a secondary AlSi6Cu2.5 alloy (STENAL Rheo1), specially developed for rheocasting. The material was studied in the as-cast condition as well as after a T6 heat treatment. The results show that the Al-Si eutectic is significantly refined by the Na addition, even after a fading time of 30 min. However, it is observed that the Na modification generally has a detrimental effect on the mechanical properties, despite the structure refinement. This is especially true in the T6 heat treated condition, where the yield strength is reduced by more than 30%. Some possible mechanisms for the degradation of mechanical performance are discussed.

Key words: rheocasting; thick-walled component; eutectic modification; mechanical properties; sodium; Al alloys