Effect of Iron Phases Crystallization on the Durability of the Bimetallic Connection Between Ring Inserts and the Piston Casting

• Autorzy: Szucki Michał , Piątkowski Jarosław , Czerepak M.

Identyfikatory

DOI

10.24425/afe.2023.144302

• Języki publikacji: EN

Abstrakty

EN

The article presents the most important causes of the unstable connection between cast iron ring inserts and the silumin casting of an engine piston. It is shown that manufacturing defects are mainly related to the alfin processing of inserts in Al-Si alloy (the so-called AS9 alloy). Exceeding the permissible iron content in AS9 alloy causes the crystallization of brittle -Al5FeSi phases. Their unfavorable morphology and large size are the main reasons for the weakening of the diffusion connection between the inserts and the piston, causing an unacceptable proportion of defective products. The study presented in this work was conducted under industrial conditions on a population of 10.000 pistons. Quality control data, production parameters, as well as the micro- and macro-structures of the cast iron inserts, and the interface area between the inserts and the silumin piston, were analyzed. Material and technological solutions have been proposed to reduce the occurrence of casting defects at the insert-piston joint. This includes the introduction of so-called "morphological correctors" of the -Al5FeSi phases, reducing the possibility of gaseous impurities in the AS9 alloy and optimizing the temperature of the alfin alloy.

Słowa kluczowe

EN

crystallization; Al-Si alloys; iron phases; pistons; automotive industry

PL

krystalizacja; stopy Al-Si; fazy krystalizacji; tłoki; przemysł motoryzacyjny

• Wydawca: Komisja Odlewnictwa Polskiej Akademii Nauk Oddział w Katowicach
• Czasopismo: Archives of Foundry Engineering
• Rocznik: 2023
• Tom: Vol. 23, iss. 2
• Strony: 112--118
• Opis fizyczny: Bibliogr. 16 poz., il., tab., wykr.

Twórcy

autor

Szucki Michał

• Technische Universität Bergakademie Freiberg, Foundry Institute, Freiberg, Germany

• https://orcid.org/0000-0002-2675-1836

autor

Piątkowski Jarosław

• Silesian University of Technology, Department of Material Technologies, Katowice, Poland

• https://orcid.org/0000-0003-3602-4605

autor

Czerepak M.

• Federal-Mogul Gorzyce sp. z o.o., Poland

Bibliografia

• [1] Szucki, M., Dziubinska, A., Winiarski, G., Majerski, K., Drozdowski, K., Górny, M. & Buras, J. (2020). Application of 2XXX and 7XXX series alloys as input material for the new casting-forging hybrid process. Indian Journal of Engineering and Materials Sciences. 27(3), 795-801. DOI: 10.56042/ijems.v27i3.45099.
• [2] Kammer, C. (2011). Aluminium Handbook. Vol. 1: Fundamentals and Materials. Beuth Verlag GmbH.
• [3] Rowe, J. (2021). Advanced Materials in Automotive Engineering. Woodhead Publishing.
• [4] Pietrowski, S. & Szymczak, T. (2004). Structure of the connection of alfin layer coating with the Al-Si cast alloy. Archives of Foundry. 4(14), 393-404. (in Polish).
• [5] Pietrowski, S. & Szymczak, T. (2006). The influence of selected technological elements on the structure of the alfinizing coat on iron alloys. Archives of Foundry. 6(19), 251-266. (in Polish). PL ISSN 1642-5308.
• [6] Pietrowski, S. (2004). Structure of alfinizing layer on the gray cast iron. Archives of Foundry. 4(11), 95-104. (in Polish). PL ISSN 1642-5308.
• [7] Crolla, D.A. (2009). Automotive Engineering. Powertrain, Chassis System and Vehicle Body. Butterworth-Heinemann.
• [8] Piątkowski, J. & Czerepak, M. (2020). The crystallization of the AlSi9 alloy designed for the alfin processing of ring supports in engine piston. Archives of Foundry Engineering. 20(2), 65-70. DOI: 10.24425/afe.2020.131304.
• [9] Schoß, J.P., Schramm, E., Schönherr, P., Mrowka, N., Schumann, H., Becker, H., Keßler, A., Szucki, M. & Wolf, G. (2023). Investigation of the formation of iron-rich intermetallic phases in Al-Si alloys via thermal analysis cooling curves, including a real-time detection for filtration process. Advanced Engineering Materials. 2201576, 1-20. DOI: 10.1002/adem.202201576.
• [10] Cao, X. & Campbell, J. (2004). The solidification characteristics of Fe-rich intermetallics in Al-11.5Si-0.4Mg cast alloys. Metallurgical and Materials Transactions. A 35, 1425-1435. DOI: 10.1007/s11661-004-0251-0.
• [11] Campbell, J. (2006). Entrainment defects. Materials Science and Technology. 22(2), 127-145. DOI: 10.1179/174328406X74248.
• [12] Bas, E.N. Alper, S., Tuncay, T., Dispinar, D. & Kirtay, S. (2022). Influence of Melt Quality on the Formation of Fe Intermetallic in A360 Alloy. Archives of Foundry Engineering. 22(3), 53-59. DOI: 10.24425/afe.2022.140236.
• [13] Pietrowski, S., Klimek, L. & Szymczak, T. (2006), Diffraction research of the alfininizing coat on iron alloys. Archives of Foundry. 6(22), 392-404. (in Polish). PL ISSN 1642-5308.
• [14] Mahta, M., Emamy, M., Daman, A., Keyvani A. & Campbell J. (2005) Precipitation of Fe rich intermetallics in Cr- and Co-modified A413 alloy. International Journal of Cast Metals Research. 18(2), 73-79. DOI: 10.1179/136404605225022928.
• [15] Baldan, R., Malavazi, J. & Couto, A.A. (2017) Microstructure and mechanical behavior of Al9Si0.8Fe alloy with different Mn contents. Materials Science and Technology. 33(10), 1192-1199, DOI: 10.1080/02670836.2016.1271966.
• [16] Shabestari, S.G. (2004) The effect of iron and manganese on the formation of intermetallic compounds in aluminum–silicon alloys. Materials Science and Engineering: A. 383(2), 289-298. DOI: 10.1016/j.msea.2004.06.022.

Uwagi

Opracowanie rekordu ze środków MEiN, umowa nr SONP/SP/546092/2022 w ramach programu "Społeczna odpowiedzialność nauki" - moduł: Popularyzacja nauki i promocja sportu (2022-2023)