Title: Deformation and fracture characteristics of complex Al-Si alloy during high speed forging under different processing conditions

Authors: Khemraj; A.K. Jha; S.N. Ojha

Addresses: Department of Mechanical Engineering, Indian Institute of Technology (Banaras Hindu University), Varanasi, 221005, India ' Department of Mechanical Engineering, Indian Institute of Technology (Banaras Hindu University), Varanasi, 221005, India ' Department of Mechanical Engineering, Indian Institute of Technology (Banaras Hindu University), Varanasi, 221005, India

Abstract: The feasibility of bulk processing of complex Al-Si alloy (Al-18Si-2.5Cu-0.6Fe) has been demonstrated in the present work. Open and closed die forging experiments have been performed using solid cylindrical billets under different conditions of working temperatures, aspect ratios and interfacial friction between top-bottom dies and test samples. The results so obtained, have been critically analysed and discussed to explain the deformation and fracture behaviour of the above Al-Si alloy. Results reveal that due to the presence of hard silicon and intermetallic particles in the alloy, the open die forging of the test sample generates severe surface cracks during deformation under cold and hot processing conditions. However, the high speed closed die forging of above complex Al-Si alloy at elevated temperatures show encouraging results. The forged component so produced is free from surface cracks and possess improved engineering properties.

Keywords: Al-Si alloy; open die forging; closed die forging; elevated working temperature; aspect ratio; surface cracks; strain hardening; primary silicon particles; intermetallic particles; deformation.

DOI: 10.1504/IJMPT.2019.096927

International Journal of Materials and Product Technology, 2019 Vol.58 No.1, pp.32 - 54

Received: 15 Aug 2017
Accepted: 17 Jun 2018
Published online: 13 Dec 2018 *

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