The roll of Iron(Fe) in

Die Casting Aluminum Alloys

Ali Molavi

Spring 2015

Some Die Casting parts

What is Die Casting method?

A kind of Die Casting Machine:

Die Casting Aluminum Alloys:

Graphite Crucible

Aluminum

Fe

MgCu

Si

Sr

Why Fe (Iron) ?

more Fe ≈ more life time of Dies

How much Fe we could add to Aluminum Alloys?

Intermetallic compound

specification

Brittle

sharp

grow in the grain

boundaries

Microstructure

How does the properties of Aluminum Alloy change with adding Fe?

Elongation

Toughness

Strength

Hardness

What is the solution ?

Cr and Mn

Change the composition of the Fe-rich intermetallic phases

The results of adding Cr and Mn are:

Change the grow mechanism of the Fe-rich intermetallic phases

Change the shape and place of the Fe-rich intermetallic phases

Schematic of the microstructure of Aluminum with Fe-rich intermetallic phases (a) without and (b) with Cr and Mn.

(a) (b)

Conclusion:

1) It is needed to have Fe in Aluminum Alloys for Die Casting to make the Die's life

longer.

2) Fe-rich intermetallic Phases will appear in the microstructure of Alloy by adding

Fe.

3) Fe-rich intermetallic phases are harmful for mechanical properties of material,

because they are brittle, sharp-edged and located in grain boundaries.

4) By adding Cr and Mn to Aluminum Alloy the Fe-rich intermetallic will be less

sharp-edged and they will move from grain boundaries into the grains.

5) As a result of adding Cr and Mn to Aluminum Alloy mechanical properties of

material will be maintained.

Any Question?

Thank you