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Effect of novel grain refiner and Ni alloying additions on microstructure and mechanical properties of Al-Si9.8-Cu3.4 HPDC castings – optimization using Multi Criteria Decision making approach

K. Ch Apparao
K. Ch Apparao
, 
Praveen Kumar Bannaravuri
Praveen Kumar Bannaravuri
, 
Kumar Swamy Pulisheru
Kumar Swamy Pulisheru
, 
E. D. Francis
E. D. Francis
, 
Kalakanda Alfred Sunny
Kalakanda Alfred Sunny
, 
Gadudasu Babu Rao
Gadudasu Babu Rao
, 
P Freedon Daniel
P Freedon Daniel
 oraz 
Anil Kumar Birru
Anil Kumar Birru
   | 25 maj 2022
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Data publikacji: 25 maj 2022
Zakres stron: 9 - 24
Otrzymano: 28 paź 2021
Przyjęty: 30 maj 2022
DOI: https://doi.org/10.2478/msp-2022-0005
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© 2022 K. Ch Apparao et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Fig. 1

Sample specimen of HPDC casting (A) Final castings with their dimensions (B) Tensile specimens with their dimensions used for the experimentations. HPDC, High pressure die casting
Sample specimen of HPDC casting (A) Final castings with their dimensions (B) Tensile specimens with their dimensions used for the experimentations. HPDC, High pressure die casting

Fig. 2

(A) XRD results of the Al-3.5FeNb-1.5C master alloy; (B) SEM microstructure of dispersed intermetallic particles extracted from Al-3.5FeNb-1.5C master alloy. XRD, X-ray diffraction
(A) XRD results of the Al-3.5FeNb-1.5C master alloy; (B) SEM microstructure of dispersed intermetallic particles extracted from Al-3.5FeNb-1.5C master alloy. XRD, X-ray diffraction

Fig. 3

Optical microscopic images of experimental castings at 720°C, 750°C, and 780°C: (A–C) without grain refiner, (D–F) 0.1 wt% of Al-3.5FeNb-1.5C, (G–I) 1.0 wt% of Al-3.5FeNb-1.5C
Optical microscopic images of experimental castings at 720°C, 750°C, and 780°C: (A–C) without grain refiner, (D–F) 0.1 wt% of Al-3.5FeNb-1.5C, (G–I) 1.0 wt% of Al-3.5FeNb-1.5C

Fig. 4

(A) Tensile strength values (B) Brinell hardness and microhardness values obtained from experimental runs. (C) and (D) show the optical microscope images of (C) R5 and (D) R25 experimental castings, which have the highest and lowest mechanical properties, respectively. (E) and (F) show the SEM and EDS images of R5, respectively
(A) Tensile strength values (B) Brinell hardness and microhardness values obtained from experimental runs. (C) and (D) show the optical microscope images of (C) R5 and (D) R25 experimental castings, which have the highest and lowest mechanical properties, respectively. (E) and (F) show the SEM and EDS images of R5, respectively

Fig. 5

Effect of process parameters on GRG. GRA, grey relational analysis
Effect of process parameters on GRG. GRA, grey relational analysis

Fig. 6

Effect of process parameters on CC. CC, closeness coefficient
Effect of process parameters on CC. CC, closeness coefficient

Fig. 7

GRG and CC value of each experimental run. CC, closeness coefficient; GRG, Grey relational grade
GRG and CC value of each experimental run. CC, closeness coefficient; GRG, Grey relational grade

Fig. 8

SEM images of Al-Si9.8-Cu3.4 alloy: Experimental runs of (A) R5 at 0.1 wt.% of Al3.5FeNb-1.5C and 0.5 wt.% of Al-6Ni with base alloy and (B) R25 at 1.0 wt.% of Al3.5FeNb-1.5C with base alloy; EDX pattern of (C) Experimental run R5 and (D) Experimental run R25
SEM images of Al-Si9.8-Cu3.4 alloy: Experimental runs of (A) R5 at 0.1 wt.% of Al3.5FeNb-1.5C and 0.5 wt.% of Al-6Ni with base alloy and (B) R25 at 1.0 wt.% of Al3.5FeNb-1.5C with base alloy; EDX pattern of (C) Experimental run R5 and (D) Experimental run R25

Fig. 9

SEM images of fracture pattern of experimental runs of (A) R5 at 0.1 wt.% of Al3.5FeNb-1.5C and 0.5 wt.% of Al-6Ni with base alloy and (B) R25 at 1.0 wt.% of Al3.5FeNb-1.5C with base alloy
SEM images of fracture pattern of experimental runs of (A) R5 at 0.1 wt.% of Al3.5FeNb-1.5C and 0.5 wt.% of Al-6Ni with base alloy and (B) R25 at 1.0 wt.% of Al3.5FeNb-1.5C with base alloy

Composition of Al-Si9.8-Cu3.4 alloy (wt.%) considered for this study

Al% Si% Cu% Fe% Ti% Mg% Ni% Zn% Pb% Sn% Mn%
86.18 9.839 3.474 0.189 0.184 0.041 0.008 0.008 0.043 0.013 0.007

Input parameters and experimental values of output characteristics along with average porosity values for L27 orthogonal array

Expt. runs Input factors Output responses Average porosity values
A (°C) B (wt.%) C (wt.%) D (°C) E (MPa) Tensile strength Brinell hardness Microhardness
1 720 0 0 230 12 218.39 85 113 0.88
2 720 0 0.5 260 18 223.76 85 116 0.53
3 720 0 5 290 24 245.50 88 119 0.36
4 720 0.1 0 260 18 239.88 90 136 0.26
5 720 0.1 0.5 290 24 249.09 91 135 0.25
6 720 0.1 5 230 12 237.31 85 136 0.47
7 720 1 0 290 24 220.53 83 112 0.85
8 720 1 0.5 230 12 214.67 83 114 0.71
9 720 1 5 260 18 208.63 86 118 0.75
10 750 0 0 260 24 217.87 85 114 0.95
11 750 0 0.5 290 12 210.73 85 116 0.77
12 750 0 5 230 18 230.46 89 116 0.49
13 750 0.1 0 290 12 230.19 86 118 0.63
14 750 0.1 0.5 230 18 237.29 88 130 0.44
15 750 0.1 5 260 24 212.70 85 120 0.62
16 750 1 0 230 18 208.26 80 106 1.01
17 750 1 0.5 260 24 218.83 85 113 0.88
18 750 1 5 290 12 201.05 80 108 0.97
19 780 0 0 290 18 219.96 85 115 0.89
20 780 0 0.5 230 24 224.58 88 125 0.33
21 780 0 5 260 12 240.50 87 118 0.49
22 780 0.1 0 230 24 238.37 88 127 0.46
23 780 0.1 0.5 260 12 240.04 90 132 0.48
24 780 0.1 5 290 18 232.57 85 114 0.46
25 780 1 0 260 12 200.27 80 107 0.99
26 780 1 0.5 290 18 199.68 85 119 0.49
27 780 1 5 230 24 224.74 84 114 0.53

Process factors and their levels used in the experiments

Parameter destination Input parameters Parameter range Level 1 Level 2 Level 3
A Molten metal temperature (°C) 720–780 720 750 780
B Al-3.5FeNb-1.5C (wt%) 0.0–0.1–1.0 0.0 0.1 1.0
C Al-6Ni (wt%) 0.0–0.5–5.0 0.0 0.5 5.0
D Die temperature (°C) 230–290 230 260 290
E Injection pressure (MPa) 12–24 12 18 24

Mean values of GRG at different levels and their main effects

Parameter destination Input parameters Level 1 Level 2 Level 3 Max/min
A Molten metal temperature (°C) 0.601 0.470 0.530 0.131
B Al-3.5FeNb-1.5C (wt%) 0.516 0.683 0.403 0.280
C Al-6Ni (wt%) 0.496 0.578 0.527 0.082
D Die temperature (°C) 0.539 0.537 0.525 0.015
E Injection pressure (MPa) 0.508 0.528 0.565 0.056

Response table of average values of CC for TOPSIS

Parameter destination Input parameters Level 1 Level 2 Level 3 Max/min
A Molten metal temperature (°C) 0.550 0.371 0.478 0.179
B Al-3.5FeNb-1.5C (wt%) 0.454 0.704 0.240 0.464
C Al-6Ni (wt%) 0.399 0.540 0.460 0.141
D Die temperature (°C) 0.499 0.463 0.435 0.036
E Injection pressure (MPa) 0.4147 0.465 0.519 0.104

TOPSIS results

Expt. runs Normalization Weighted normalization Separation CC
Tensile strength Brinell hardness Vickers hardness Tensile Brinell Vickers S− S+
1 0.187 0.191 0.183 0.062 0.064 0.061 0.016 0.008 0.324
2 0.192 0.191 0.188 0.064 0.064 0.063 0.014 0.010 0.416
3 0.211 0.198 0.192 0.070 0.066 0.064 0.010 0.016 0.628
4 0.206 0.202 0.220 0.069 0.067 0.073 0.003 0.021 0.886
5 0.214 0.204 0.218 0.071 0.068 0.073 0.001 0.023 0.972
6 0.204 0.191 0.220 0.068 0.064 0.073 0.005 0.020 0.786
7 0.189 0.187 0.181 0.063 0.062 0.060 0.016 0.007 0.306
8 0.184 0.187 0.184 0.061 0.062 0.061 0.017 0.007 0.283
9 0.179 0.193 0.191 0.060 0.064 0.064 0.016 0.008 0.350
10 0.187 0.191 0.184 0.062 0.064 0.061 0.016 0.008 0.333
11 0.181 0.191 0.188 0.060 0.064 0.063 0.016 0.008 0.321
12 0.198 0.200 0.188 0.066 0.067 0.063 0.012 0.013 0.511
13 0.197 0.193 0.191 0.066 0.064 0.064 0.012 0.012 0.500
14 0.204 0.198 0.210 0.068 0.066 0.070 0.005 0.018 0.779
15 0.182 0.191 0.194 0.061 0.064 0.065 0.014 0.009 0.391
16 0.179 0.180 0.171 0.060 0.060 0.057 0.022 0.003 0.110
17 0.188 0.191 0.183 0.063 0.064 0.061 0.016 0.008 0.334
18 0.172 0.180 0.175 0.057 0.060 0.058 0.022 0.001 0.059
19 0.189 0.191 0.186 0.063 0.064 0.062 0.015 0.009 0.370
20 0.193 0.198 0.202 0.064 0.066 0.067 0.009 0.014 0.598
21 0.206 0.196 0.191 0.069 0.065 0.064 0.010 0.014 0.582
22 0.204 0.198 0.205 0.068 0.066 0.068 0.006 0.017 0.727
23 0.206 0.202 0.213 0.069 0.067 0.071 0.004 0.020 0.845
24 0.200 0.191 0.184 0.067 0.064 0.061 0.014 0.011 0.452
25 0.172 0.180 0.173 0.057 0.060 0.058 0.022 0.001 0.032
26 0.171 0.191 0.192 0.057 0.064 0.064 0.018 0.008 0.309
27 0.193 0.189 0.184 0.064 0.063 0.061 0.015 0.009 0.380

Normalized data and deviation sequence values of the following characteristics

Run Deviation Tensile strength Sequences Brinell hardness (Δ0i) Microhardness GRC Tensile strength Brinell hardness Microhardness GRG Rank
1 0.62 0.55 0.77 0.45 0.48 0.39 0.44 20
2 0.47 0.55 0.67 0.49 0.48 0.43 0.47 13
3 0.07 0.27 0.57 0.87 0.65 0.47 0.66 6
4 0.19 0.09 0.00 0.73 0.85 1.00 0.86 2
5 0.00 0.00 0.03 1.00 1.00 0.94 0.98 1
6 0.24 0.55 0.00 0.68 0.48 1.00 0.72 4
7 0.58 0.73 0.80 0.46 0.41 0.38 0.42 23
8 0.69 0.73 0.73 0.42 0.41 0.41 0.41 24
9 0.82 0.45 0.60 0.38 0.52 0.45 0.45 15
10 0.63 0.55 0.73 0.44 0.48 0.41 0.44 18
11 0.51 0.55 0.67 0.39 0.48 0.43 0.43 21
12 0.38 0.18 0.67 0.57 0.73 0.43 0.58 9
13 0.38 0.45 0.60 0.57 0.52 0.45 0.52 11
14 0.24 0.27 0.20 0.68 0.65 0.71 0.68 5
15 0.74 0.55 0.53 0.40 0.48 0.48 0.46 14
16 0.83 1.00 1.00 0.38 0.33 0.33 0.35 25
17 0.61 0.55 0.77 0.45 0.48 0.39 0.44 19
18 0.97 1.00 0.93 0.34 0.33 0.35 0.34 26
19 0.59 0.55 0.70 0.46 0.48 0.42 0.45 16
20 0.49 0.27 0.37 0.50 0.65 0.58 0.58 10
21 0.17 0.36 0.60 0.74 0.58 0.45 0.59 8
22 0.22 0.27 0.30 0.70 0.65 0.63 0.66 7
23 0.18 0.09 0.13 0.73 0.85 0.79 0.79 3
24 0.33 0.55 0.73 0.60 0.48 0.41 0.49 12
25 0.99 1.00 0.97 0.34 0.33 0.34 0.34 27
26 1.00 0.55 0.57 0.33 0.48 0.47 0.43 22
27 0.49 0.64 0.73 0.50 0.44 0.41 0.45 17

Results’ comparison at initial and optimal levels by GRA and TOPSIS methods

S. No Parameter Initial value Predicted value Experimental value
A2, B1, C1, D2, E3 A1, B2, C2, D1, E3 A1, B2, C2, D1, E3
1 Tensile strength 218.388 – 249.085
2 Brinell hardness 85 – 91
3 Vickers microhardness 113 – 135
4 Grey relational grade 0.4396 0.8087 0.9792
5 Closeness coefficient 0.3242 0.9481 0.9715
6 Improvement of GRG – 0.5396 –
7 Improvement of CC - 0.6473 –
eISSN:
2083-134X
Język:
Angielski
Częstotliwość wydawania:
4 razy w roku
Dziedziny czasopisma:
Materials Sciences, other, Nanomaterials, Functional and Smart Materials, Materials Characterization and Properties
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