Silicon spheroidization treatment of thixoformed Al-Si-Mg alloys

Al-Si-Mg alloys are commonly used in the automobile industry because of their outstanding mechanical properties and corrosion resistance. The need of lighter and safer cars is the driving force behind research in the area of high strength light metal safety part applications. The strength level can be tuned by varying the amount of alloyed magnesium. Usually if strength is increased, ductility will decrease. Following the demands of the automotive industry, safety parts should have a minimum fracture elongation of 15% and a minimum yield strength of 150 MPa. The huge hurdle is the 15% fracture elongation which can not be reached by sand or die casting, but some relatively new alternative casting technologies, like Thixocasting or New Rheocasting, yield encouraging ductility values. Recent research activity has focused on increasing strength and ductility, but so far the results have not yet been satisfying. This paper presents investigations on the spheroidization process of eutectic silicon and its positive effect on mechanical properties. It is shown that the spheroidization process is already finished after minutes of exposure to heat treatment. Metallographical and quantitative microstructural analysis is used to describe the growth and spheroidization process of the silicon crystals. Specimens of THIXALLOY(R)630 (A356) thixocast components were heat treated for varied periods of time, aged and tested. Results show amazing improvements of ductility and strength in comparison to the as cast state. Maximum values of 18% fracture elongation and 230 MPa yield strength are reached.