Effect of Mold Type on the Microstructure and Tensile Properties of A356 Alloy

The present study was performed on castings obtained from A356 alloy melts subjected to different melt treatments (degassing, modification, grain refining). The castings were prepared using three different processes/molds: lost foam, ASTM standard metallic, and end-chill refractory molds. An examination of samples sectioned from the cylinder head/lost foam casting showed that the secondary dendrite arm spacing (SDAS) depends on the sample location in the cylinder head, with bolt boss and combustion chamber sections exhibiting SDAS values of 52 and 86 µm, respectively, versus 26 µm for the ASTM metallic mold samples, and from 25 to 85 µm with increasing distance from the end-chill, along the height of the refractory mold. Grain refining (Al-4 %B) leads to redistribution of porosity in the casting, as the AlB2 particles of the grain refiner act as sites for the precipitation of hydrogen gas bubbles, resulting in finer pores. This observation is independent of the mold type. In the presence of modifier, Sr–B interaction causes loss in the available Sr and B for modification and grain refining, resulting in a heterogeneous distribution of the eutectic silicon particles. Although increasing the solidification rate reduces the percentage porosity, it also leads to segregation of hydrogen at the solid/liquid interface in the case of directional solidification obtained with the end-chill mold, so that the porosity is the outcome of the solidification rate and the hydrogen content. The tensile properties of the A356 alloy are controlled by the size and morphology of the eutectic silicon particles more than by the addition of grain refiner. The difference in tensile properties obtained using the three molds is essentially attributed to % porosity (shrinkage, gas, and presence of residual pyrolysis) and SDAS. The use of proper melt treatments and the ASTM standard metallic (tensile test bar) mold could produce strength values that are 170 % higher than that obtained from the lost foam castings.