PRODUCTION ENGINEERING ARCHIVES 14 (2017) 3-6

PRODUCTION ENGINEERING ARCHIVES

ISSN 2353-5156 (print) Exist since 4rd quarter 2013
ISSN 2353-7779 (online) Available online at www.qpij.pl/production-engineering-archives

Quality control of cylinder head casting

Eva Tillová1, Mária Chalupová1, Lenka Kuchariková1
l
University of Žilina, Faculty of Mechanical Engineering, Department of Materials Engineering, Univerzitná 8215/1, 010 26 Žilina,
Slovakia, e-mail: [email protected]

Article history Abstract

Received 16.01.2017 New challenges for the Aluminium alloys used for the production of castings for automotive engine
Accepted 10.03.2017 components result from an evolutionary trend of internal combustion engines towards higher specific
Available online 03.04.2017 power output. Cylinder heads, in particular, have to withstand higher operating temperature and
Keywords stress levels. Present work describes quality control of microstructure (Si-morphologhy and Si-size)
AlSi cast alloy, and mechanical properties (UTS, elongation, Brinell hardness) of cylinder head casting as effect of
heat treatment, different T6 heat treatment (solution heat treatment time - 2, 3, 4, 5, 6, 7 hours). The data obtained
quality control, from this study will be used to improve process control, and to help the selection of heat treatment of
microstructure, the casting for future products.
mechanical properties

1. Introduction distribution of the eutectic silicon particles (COMALCO 1997),

as well as the morphologies and amounts of intermetallic
Aluminium castings are widely used in automotive industry phases (TAYLOR J.A. 2013) present. These parameters are
for several components such as engine blocks and cylinder completely changed after heat treatment, which, in turn,
heads, which are produced in high volumes, owing to their influences the resultant mechanical properties (FAN K. L.
favourable combination of low weight, easy machinability, 2013, MOUSTAFA M. A. 2003, PARAY F. 1994, SJŐLANDER E.
recyclability and low cost (TILLOVÁ E. 2009). In the last 2010, TILLOVÁ E. 2011, ULEWICZ R. 2013).
years the evolution of internal combustion engines has been The present study is part of a larger research project which
driven mainly by the need to meet new stringent emissions was conducted to evaluate the heat treatment of an
standards (like Euro 5 or future Euro 6 in Europe) and to AlSi7Mg0.3 cast alloy used in the manufacture of engine
improve fuel economy of the vehicles aiming to reduce the blocks and cylinder heads. The study was conducted on as-
amount of CO2, which is considered a “greenhouse gas” with cast and heat treated samples that were cut from the bulk-
potential effect on global warming, released to the ambient heads of cylinder heads. These samples were tested either in
(MOLINA R. 2011). the as-cast and heat treated conditions.
Development in aluminium alloys and optimization of cast-
ing techniques has led to improved material properties and
functional integration which enable aluminium castings to
2. Experimental procedure
satisfy the new market requirements and has allowed replac- For the experimental work cylinder head castings (Fig.1)
ing, in many cases, engine components made with heavy cast that were produced from the most popular A356 alloy were
iron alloys. Nevertheless, requirements for new products are used. Chemical composition of AlSi7Mg0.3 (wt. %) is 7.1
becoming more and more challenging for conventional alu- Si; 0.38 Mg; 0.095 Ti; 0.12 Fe; 0.005 Mn; 0.001 Cu; 0.025
minium alloys and their further improvement or the intro- Sr; 0.0008 Na; 0.0001 Sb; 0.002 Ca; 0.003 Zn; base of Al.
duction of new alloys are under evaluation (MOLINA R. 2011, The structure refinement is one of the most important
GONZÁLEZ E. 2013). methods for improving the strength and ductility of
The mechanical properties of an Al-Si cast alloy are main- Al-Si castings (ROMANKIEWICZ R. 2014). Melt was grain
ly determined by its cast structure (ASM 2002) and the mi- refined with Tiboral 6 masteralloy. Modification was
crostructural characteristics such as the grain size, dendrite achieved with AlSr 90/10 masteralloy. An addition of stron-
arm spacing (DAS) (ZHANG B. 2003), the size, shape and tium can cause a transition of the eutectic silicon phase from

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coarse flakes to fine fibber and consequently improve the chanical properties. Magnesium’s role is to strengthen and
mechanical properties, especially the ductility. harden aluminium castings. Silicon combines with magnesi-
A standard heat treatment used for engine blocks is solu- um to form the hardening phase, Mg2Si that provides the
tion heat treatment lasting 7 hours at the temperature of strength-hening of this alloy. According to the increase of the
530°C, quenching in water at 20°C and precipitation harden- strength, the hardness is also improved.
ing for 4 hour at 160 °C. Experimental samples were solution The effect of heat treatment on mechanical properties of the
treated by different solution time (2, 3, 4, 5, 6 and 7 hours) at AlSi7Mg0.3 alloy is shown in Fig. 2 and Fig. 3. Utility ulti-
530°C ± 5°C, quenched in water at 20°C ± 2°C and precipi- mate tensile strength (UTS) and hardness (HBS) of specimens
tation hardened for 4 hour at 160 °C± 5°C. increase with solution treatment time. Elongation with solution
Experimental samples for a tensile test were cut from the treatment time decreases.
bulkheads of engine blocks (Fig. 1). The tensile test were The required mechanical properties for a typical alumini-
carried out on a tensile machine ZDM 30 at 21 °C following um engine block includes an ultimate tensile strength of
the STN EN ISO 6892-1 in as-cast state and after heat treat- 245 MPa, yield stress of 215 MPa, and fatigue strength of
ment; these specimens were of 14 mm in diameter by 60 MPa. These values meet all experimental heat treated
120 mm in gauge length. Values of ultimate tensile strength samples.
in dependence on heat treatment were determined by the
average value of three test bars. Hardness measurement was 350
performed by a Brinell hardness tester with the load of UTS, MPa HBS
62.5 kp, 2.5 mm diameter ball and the dwell time of 15 s 300
according to standard STN EN ISO 6506-1. The Brinell 250
hardness value at each state was obtained by the average of
at least six measurements. 200

150

100

50

0
0 2 3 4 5 6 7
Fig. 2. Effect of solution treatment time on utility tensile
strength and Brinell hardness of AlSi7Mg0.3 alloy

12
A5,% Si-size, mm2
10

8
Fig. 1. The experimental cylinder head casting and part of casting
for tensile test bar 6

Metallographic samples were sectioned from the tensile 4

test bars (after testing), standard prepared for metallographic
2
observations (wet ground on SiC papers, DP polished with
3 μm diamond pastes followed by Struers Op-S) and etched 0
by 0.5 % HF (TILLOVÁ E. 2011). The microstructures were 0 2 3 4 5 6 7
studied using an optical microscope (Neophot 32). Some Fig. 3. Effect of solution treatment time on elongation
samples were also deep-etched for 30 s in HCl solution in and Si-particle area of AlSi7Mg0.3 alloy
order to reveal the three-dimensional morphology of the
silicon phase and observed on SEM. The silicon particle cha- Higher strength but lower elongation accounts the specimens
racteristics (average Si particle area (µm2)) were measured for 3 and 5 hours solution heat treatment, next increases. This
using a Nis Elements 3.0 image analyser. uncorrelated trend between strength properties and elongation
can be attributed to the following three factors: 1) effect of
3. Results and discussion dissolved Mg2Si; 2) effect of Si content dissolved in the Al-
matrix; and 3) effect of Si morphology. The trend of increase
Alloys of the A356 type (AlSi7Mg0.3) are usually heat in UTS and decrease in elongation observed in this study is
treated in order to develop higher mechanical properties. The in good agreement with other researcher (CACERES C.H. ET
influence of heat treatment parameters on solution heat AL. 1999, SJÖLANDER E. 2010).
treatment and artificial aging was investigated in terms of
changes in the eutectic silicon morphology and in the me-

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This type of alloy is characterized by dendrite structure with

a homogeneous distribution of eutectic silicon see Fig. 4.
By the addition of appropriate elements such as strontium in
the liquid metal, it is possible to modify silicon morphological
structure from lamellar to globular du-ring the solidification.
This modification treatment improves the mechanical proper-
ties of the Al-Si alloy by reducing the notching effect of needle
shaped natural eutectic silicon (TILLOVÁ E. 2011).
The as-cast microstructure of AlSi7Mg0.3 consists of
α-phase (Al-matrix), eutectic (mixture of: eutectic silicon and c) solution time 4 h
-matrix) and various types of Fe- and Mg- rich intermetallic
phases. The effects of solution treatment time on eutectic
silicon morphology are shown in Fig.4b-d. Solution treatment
causes a substantial degree of spheroidisation and coarsening
in modified eutectic phases. Eutectic silicon in as-cast state
(Fig. 4a) has undergone necking and separated into segments.
During the first hour of solution treatment (Fig. 4b) Si particles
gradually fragmented, rapidly spheroidised, and undergo
coarsen. Prolonged solution treatment leads to a significant
coarsening of the Si particles (Fig. 4c, Fig. 4d). Due to the
presence of Sr, the particles in the modified material are al- d) solution time 7 h
ready fine and rounded, and they coarsen with an area increas- Fig. 4. Effect of solution treatment time on microstructure
ing from 2.14 to 5.27 m2 (Fig. 3). of AlSi7Mg0.3 alloy, etch. 0.5 % HF and deep etch. HCl, SEM
In Fig. 3, Fig. 4b, Fig. 4c and Fig. 4d we can see that pro-
longed solution treatment time (more than 5 hours) leads to a Solution treatment causes substantial degree of spheroidisa-
coarsening of the Si particles, while the numerical Si density tion and coarsening modified eutectic phases. Spheroidisation
decreases. process of the silicon through heat treatment takes place in two
stages: fragmentation or dissolution of the eutectic branches
and spheroidisation of the separated branches. The former has
the greatest effect on the time required to complete spheroidi-
sation and is strongly affected by the morphology of the Si
particles. The rate of spheroidisation depends on the size of the
fragmented segments.
Heat treatment of Al-Si-Mg alloy causes precipitation
hardening (Mg2Si), spheroidisation of silicon crystals, in-
creased bonding between the hard second phase silicon parti-
cles and aluminium.
a) as-cast state (untreated)
4. Conclusions
Heat treatment improves mechanical properties of the en-
gine block casts from AlSi7Mg0.3 (A356) alloy. Tensile
strength and hardness of specimens increase with solution
treatment time. The hardness is a reflection of solution
strengthening and silicon particle distribution in matrix.
Solution temperature 530oC and 5 hours solution time is
appropriate to obtain better morphology and distribution of
Si particles in microstructure of the engine block casts.
b) solution time 2 h Solution treatment blunts the sharp edges of Si particles
and promotes fracture resistance. Prolonged solution treat-
ment (more than 5 hours) leads to a coarsening of the Si
particles, while the numerical Si density decreases. As the
particle density decreases, a fewer number of sites are avail-
able for crack nucleation, hence, the fracture properties are
improved.

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The data obtained from this study will be used to improve 7. MOUSTAFA M.A. ET AL. 2003. Effect of solution heat treatment and
additives on the microstructure of Al-Si (A413.1) automotive alloys.
process control, and to help the selection of the heat treat-
Journal of Materials Science 38, 4507-4522.
ment for future products. 8. PARAY F., GRUZLESKY J. E. 1994. Microstructure - mechanical proper-
ty relationships in 356 alloy. Cast Metals 7 (1), 29- 40.
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tion for structure and impact resistance of silumin AlSi11. Production
The authors acknowledge the financial support of the project Engineering Archives 3(2), 6-9.
10. SJŐLANDER E., SEIFEDDINE S. 2010. The heat treatment of Al-Si-Cu-Mg
VEGA No 1/0533/15 and European Union - the Project casting alloys. Journal of Materials Processing Technology 210, 249-
ITMS: 26220220154. 1259.
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casting alloys. Procedia Materials Science 1, 19-33.
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氣缸蓋鑄件質量控制
關鍵詞 摘要
AlSi鑄造合金， 用於生產汽車發動機部件鑄件的鋁合金的新挑戰來自內燃機朝向更高比功率輸出的演變趨勢
熱處理， 特別地，氣缸蓋必須承受更高的操作溫度和應力水平。
質量控制， 目前的工作描述了缸蓋鑄件的微觀結構（Si-形態和Si-
微觀結構， 尺寸）和機械性能（UTS，伸長率，布氏硬度）的質量控製作為不同T6熱處理（固溶熱處理時
機械性能 間-2, 3, 4, 5, 6, 7小時。
從該研究獲得的數據將用於改進過程控制，並且幫助選擇用於未來產品的鑄件的熱處理。

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