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C, respectively. It
was established that the intermediate die temperature of 250
C produced the highest tensile properties and that the presence of zirconium
did not improve the as-cast properties of the squeeze cast alloy. The highest UTS value obtained for the zirconium-free RZ5DF alloy was
198 MPa compared to 195 MPa for the ZR5 alloy. These UTS value were approximately 50% higher than those for material cast under
atmospheric pressure.
2003 Elsevier B.V. All rights reserved.
Keywords: Magnesium alloys; Squeeze casting; Mechanical properties; Grain renement
1. Introduction
Magnesium alloys have properties that make them attrac-
tive for certain applications. However, even complex alloys
have limitations in respect of strength, stiffness and abra-
sion resistance. It is possible that these limitations can be
overcome by using metal matrix composites (MMC) with
a magnesium-based alloy. Although several manufacturing
processes can be used to produce such composites, the cast-
ing route is especially attractive given its ability to produce
complex shapes. However, in order to obtain the benets
of reinforcement, the casting process must deliver castings
that are free of defects such as gas or shrinkage porosity.
Squeeze casting is capable of delivering such castings and
consequently has been used to produce cast MMC. Before
advocating squeeze casting for MMC production, however
it is necessary to understand the inuence of process vari-
ables on the base alloy and that was the purpose of the work
described in this paper.
C, duration of applied
pressure at 25 s, and delay before application of pressure at
4 s. Following establishment of the optimum applied pres-
sure (at 60 MPa), the inuence of metal pouring and die
temperatures was investigated whilst the applied pressure,
delay and duration were kept constant. The pouring tem-
peratures investigated were 720, 750 and 780
C and the
die temperatures were 225, 250 and 275
C. The selection
of the experimental ranges for pouring and die tempera-
tures was guided by the literature. Pure magnesium melts
at 640
C.
3.2. Series 2 experiments: the evaluation of squeeze cast
RZ5DF alloy
3.2.1. Tensile properties
The relationships between pouring temperature, die tem-
perature and tensile properties are shown in Figs. 6 and 7.
3.2.2. Metallography
Metallographic specimens were examined to evaluate the
effects of pouring and die temperature on the RZ5DF mi-
crostructure. The examinations were conducted on speci-
mens selected from those that had the highest, intermediate
and lowest UTS values. The structure associated with the
highest UTS value is shown in Fig. 8.
3.3. Series 3 experiments: the evaluation of squeeze cast
RZ5 alloy
3.3.1. Tensile properties
The relationships between pouring temperature, die tem-
perature and tensile properties are shown in Figs. 9 and 10.
3.3.2. Metallography
Metallographic examinations were conducted to evaluate
the effects of pouring and die temperature on the squeeze cast
RZ5 microstructure. These examinations were conducted on
specimens selected from those that produced the highest, in-
termediate and lowest UTS values. Fig. 11 shows the struc-
ture associated with the highest UTS value.
4. Discussion
As in all casting processes, the rate of solidication in
squeeze casting is determined primarily by the rate at which
heat is transferred by the metal to the die. In most casting
processes, heat ow is controlled to a signicant extent by
resistance at the metalmould interface. The thickness of the
solid metal that forms is typically a parabolic function of
time, being initially very rapid and then decreasing as the
mould is heated [14]. However, in squeeze casting, the pres-
sure applied through the punch promotes an intimate con-
tact between the metal and die and this largely overcomes
the resistance to heat ow. According to Campbell [20], the
transfer of heat across the interface can be enhanced signif-
icantly in squeeze casting. For squeeze cast aluminium, the
gure may be up to 60,000 W/m
2
K compared to the more
normal values of 1001000 W/m
2
K. The heat to be trans-
ferred consists of the volumetric heat of fusion (the major
component) and the superheat. Higher pouring temperatures
increase the superheat contribution. It should be noted that
whilst the volumetric heat of fusion for magnesium is ap-
proximately 15% lower than that for aluminium, the specic
heat for the liquid metal is approximately 15% higher for
magnesium than aluminium. The temperature of the die in-
uences its capacity to absorb heat. However, it is the dies
M.S. Yong, A.J. Clegg / Journal of Materials Processing Technology 145 (2004) 134141 137
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138 M.S. Yong, A.J. Clegg / Journal of Materials Processing Technology 145 (2004) 134141
-
-
-
-
-
-
-
------
140
120
100
80
60
40
20
0
0.1 20 40 60 80 100 120
Applied Pressure (MPa)
G
r
a
i
n
S
i
z
e
(
m
)
Fig. 5. Inuence of applied pressure on the cell size of the squeeze cast
RZ5DF alloy.
---
-
-
-
-
-
-
-
-
-
205
200
195
190
185
180
175
170
165
160
225
0
C 250
0
C 275
0
C
Die Temperature (degree C)
U
l
t
i
m
a
t
e
T
e
n
s
i
l
e
S
t
r
e
n
g
t
h
(
M
P
a
)
Pouring Temp (
0
C)
720
0
C
750
0
C
780
0
C
Fig. 6. The effects of pouring and die temperatures on ambient temperature
UTS (RZ5DF alloy).
Fig. 8. Optical microstructure of the squeeze cast RZX5DF alloy with the highest UTS of 198 MPa at ambient temperature, providing an average cell
size of 18 m.
-
-
-
-
-
-
-
-
-
-
---
720
0
C
750
0
C
780
0
C
Pouring Temp (
0
C)
14
12
10
8
9
8
7
6
5
4
3
225
0
C 250
0
C
275
0
C
%
A
r
e
a
R
e
d
u
c
t
i
o
n
%
E
l
o
n
g
a
t
i
o
n
Die Temperature (degree C)
Fig. 7. The effects of pouring and die temperature on percentage elongation
and percentage area reduction of RZ5DF alloy specimens tested at ambient
temperature.
thermal diffusivity that exerts the major inuence on the rate
of solidication [14].
From the results, it would appear that the optimum ap-
plied pressure range is from 50 to 100 MPa. The low UTS
values produced by applied pressures below 40 MPa are pri-
marily the consequence of porosity present in the castings
because the pressure acting on the molten metal was insuf-
cient for its elimination (Fig. 2). As the applied pressure was
increased to 60 MPa, not only was porosity reduced, the rate
of cooling was increased and the cell size reduced with a
concomitant improvement in tensile properties. This is em-
phasised when the microstructures of castings produced by
different applied pressures, shown in Fig. 4, are compared.
An average cell size of 127 m was produced by gravity
M.S. Yong, A.J. Clegg / Journal of Materials Processing Technology 145 (2004) 134141 139
--
-
-
-
-
-
-
-
-
-
205
200
195
190
185
180
175
170
165
160
225
0
C 250
0
C 275
0
C
Die Temperature (degree C)
U
l
t
i
m
a
t
e
T
e
n
s
i
l
e
S
t
r
e
n
g
t
h
(
M
P
a
)
Fig. 9. The effects of pouring and die temperature on UTS at ambient
temperature (RZ5 alloy).
-
-
-
-
-
-
-
-
-
---
12
11
10
9
8
8
7
6
5
4
225
0
C 250
0
C 275
0
C
Die Temperature (degree C)
%
A
r
e
a
R
e
d
u
c
t
i
o
n
%
E
l
o
n
g
a
t
i
o
n
720
0
C
750
0
C
780
0
C
Pouring Temp (
0
C)
Fig. 10. The effects of pouring and die temperature on percentage elongation and percentage area reduction of RZ5 alloy specimens tested at ambient
temperature.
Fig. 11. Optical microstructure of the squeeze cast RZ5 alloy with the highest UTS of 195 MPa at ambient temperature, providing an average cell size
of 21 m.
die-casting at atmospheric pressure (0.1 MPa) but the cell
size was reduced to 21 m at an applied pressure of 60 MPa,
a signicant six-fold reduction in cell size. The reduction
in cell size was attributed to the intimate contact between
the melt and die wall that promoted rapid heat transfer, as
applied pressure was increased.
Solidication is a process of nucleation and growth and
this process is inuenced by the rate at which heat is trans-
ferred which in turn inuences the structure and properties
of the casting. In squeeze casting, we might expect solidi-
cation to commence as soon as the metal contacts the die,
i.e. before pressure is applied. Once pressure is applied, heat
transfer is promoted and concurrently the temperature of
the metal increases, as predicted by the ClausiusClapeyron
equation and this might, in combination with the long
140 M.S. Yong, A.J. Clegg / Journal of Materials Processing Technology 145 (2004) 134141
freezing range of the alloys, be expected to promote con-
stitutional undercooling. Such conditions are normally con-
ducive to the formation of a dendritic structure but the co-
pious nucleation promoted by the massive chilling effect of
squeeze casting [7] produces an extremely ne casting struc-
ture.
The results for the RZ5DF alloy suggest that the high-
est UTS was associated with the higher pouring temperature
(780
C. A
steep temperature gradient, a consequence of combining a
high pouring temperature with a low die temperature, should
yield a ne microstructure and produce higher mechanical
properties [2124]. Conversely, castings produced with a
shallow temperature gradient are likely to have a large uni-
form cell structure, which will generally lead to lower me-
chanical properties. However, the results for the RZ5 alloy
suggest that, although the intermediate die temperature was
still as important, the highest UTS was obtained when this
was combined with the intermediate pouring temperature
(750