The aim of the present work is the study of T6 heat treatment of A354 (Al-Si-Cu-Mg) casting alloy. The heat treatment was optimized by maximizing mechanical strength of the alloy while keeping the treatment cost effective, reducing treatment time and temperature. Due to the presence of low melting compounds, a double stage solution treatment was proposed. The first stage was aimed at the homogenization and dissolution of the low melting phase while a second stage at a higher temperature was evaluated to foster dissolution of Cu/Mg rich intermetallics and keep the solution time and temperature as low as possible. Microstructural investigations were performed through optical and electronic microscopy, which allowed the assessment of the evolution of intermetallic phases during the solution treatment. Artificial aging was studied at different temperatures from 160 °C to 210 °C where the peak aging condition was identified. Over aging of the heat treated alloy was evaluated by soaking T6 samples at 200, 245, and 290 °C for up to 168 h. Tensile behavior of the T6 and over-aged alloy (i.e., after soaking at 210 °C for 50 h) was evaluated at room temperature. Results showed that the proposed treatment allowed the enhancement of mechanical properties of the alloy in comparison to industrial practice treatment, maintaining a good level of ductility and conferring a superior resistance to long-term high temperature exposure.

Cast aluminum alloys are widely used in the automotive field for the production of complex engine parts. However, the mechanical properties of heat-treatable alloys (e.g., Al–Si–Mg or Al–Si–Cu–Mg) are negatively affected by prolonged exposure to temperatures higher than about 200 °C. To date, several researchers have proposed the addition of alloying elements, such as Sc or Hf, for enhancing the high temperature behavior of cast Al alloys, while Mo has not been widely investigated. The present study aimed to assess the effects of Mo addition on microstructure, mechanical properties, and thermal stability of the A354 alloy. Samples of A354 alloy with different amount of Mo (in the range 0.1 to 0.8 wt %) were produced. The casting conditions and heat treatment parameters were optimized by means of optical and scanning electron microscopy, thermal analysis and hardness tests. Tensile tests highlighted that Mo induces a moderate increase of yield strength at room temperature (about 10%), but no appreciable improvement in the performance of the alloy at 250 °C was observed.

Al-Si-Cu alloys are the most widely used materials for high-pressure die casting processes. In such alloys, Fe content is generally high to avoid die soldering issues, but it is considered an impurity since it generates acicular intermetallics (β-Fe) which are detrimental to the mechanical behavior of the alloys. Mn and Cr may act as modifiers, leading to the formation of other Fe-bearing particles which are characterized by less harmful morphologies, and which tend to settle on the bottom of furnaces and crucibles (usually referred to as sludge). This work is aimed at evaluating the influence of sludge intermetallics on the fatigue behavior of A380 Al-Si-Cu alloy. Four alloys were produced by adding different Fe, Mn and Cr contents to A380 alloy; samples were remelted by directional solidification equipment to obtain a fixed secondary dendrite arm spacing (SDAS) value (~10 μm), then subjected to hot isostatic pressing (HIP). Rotating bending fatigue tests showed that, at room temperature, sludge particles play a detrimental role on fatigue behavior of T6 alloys, diminishing fatigue strength. At elevated temperatures (200 °C) and after overaging, the influence of sludge is less relevant, probably due to a softening of the α-Al matrix and a reduction of stress concentration related to Fe-bearing intermetallics.

The effect of Zr addition on overaging and tensile behavior in a 2618 Al–Cu–Mg–Ni–Fe alloy has been investigated in this study. The chemical composition of the base 2618 alloy, containing ~0.1 wt % of Zr, was modified by adding Zr to reach the target content of 0.25 wt %. Cast bars were T6 heat-treated according to industrial parameters, involving soaking at 525 °C for 8 h, quenching in hot water (50 °C), and artificial aging at 200 °C for 20 h. Both the T6 2618 and 2618 + Zr alloys were overaged at 250 and 300 °C for up to 192 h, to evaluate the decrease in hardness with high temperature exposure time. The tensile behavior of the alloys was investigated in the overaged condition, both at room temperature and at 250 °C. The microstructure of the as-cast and solution-treated samples was investigated by optical and scanning electron microscopy, while the precipitate microstructure at the nanoscale was analyzed by transmission electron microscopy in overaged condition. Experimental data revealed that the presence of 0.25 wt % Zr does not induce modifications at the macroscale on the microstructure of 2618 alloy while, at the nanoscale, the presence of Zr-based precipitates was observed. The overaged Zr-enriched alloy showed increased yield and ultimate tensile strength in comparison to the base alloy, at equal heat treatment condition, both at room temperature and 250 °C.

This study focuses on the role of Mo addition on the mechanical properties of an Al-Si-Cu-Mg alloy in as-cast and heat-treated condition at ambient and elevated temperature. Addition of 0.4 to 0.6 wt.% Mo forms Mo-bearing dispersoid particles which have a relatively high melting point and improve high temperature tensile strength. Ductility suffered in the presence of Mo-bearing particles. Trace addition of Mo up to 0.6 wt.% has a negligible influence on the yield strength and hardness of Al-Si-Cu-Mg alloy in as-cast and heat-treated conditions at ambient temperature and 250 °C.