Microstructural Analysis and Simulation Studies of Semi-solid Extruded Al–Cu–Mg Powder Metallurgy Alloys

Semi-solid extrusion of Al–Cu–Mg Powder Metallurgy (P/M) alloys had simulated under three different temperatures and extrusion angles in the present investigation. Al, Cu, and Mg powders were taken in different ratios in order to produce strong and light weight P/M alloys. Billets were prepared with an aspect ratio of one (φ 15 × 15 mm) to get good deformation results. Al–4Cu–0.5Mg alloy composition was optimized to do semi-solid extrusion after considering density, hardness, and strength as best parameters to optimize. Alloys were sintered at 550 °C and prepared samples with Initial Relative Density (IRD) of 90% for densification and deformation studies. The working temperature range for semi-solid extrusion test was derived from TG/DTA analysis. Extrusion tests were performed on a hydraulic press under different deformation temperatures (550, 575 and 600 °C) and different solid fractions (0.93, 0.76, and 0.56) respectively. All the extrusion tests were performed with a low extrusion ratio of 1.44, die approach angles of 30°, 45°, and 60° and strain rate of 0.1 s⁻¹. High density (>95%) and high hardness (>1000 MPa) extruded Al alloys were produced with good microstructures. Microstructural analyses were done for all Al alloys and found uniform distribution of grains at different temperatures. Dynamic recrystallization of grains was found with increasing liquid fraction during extrusion experiments. For an accurate prediction of microstructure evolution the strain rate, strain and temperature have to be considered and these can be calculated by FEM simulation. Simulation studies had been performed at three selected temperatures using Deform-2D software. Simulation and experimental results have been shown good agreement between them.