International Journal of Scientific & Engineering Research, Volume 6, Issue 3, March-2015

ISSN 2229-5518
1530

Component Crack Analysis of high pressure die casting aluminum alloy (Alsi9cu )

Satish kumar Manocha

Designation – Dy. Manager
Department - R&D
Name of industries – Rico auto industries

ABSTRACT:
Crack Analysis of the high pressure die casting Alsi9cu aluminum alloy component. The study is
aimed in the project or research work. Especially industry based problem is decides to study in detail
Technical solution for minimizing cracks in casting parts and find out the causes of crack failure
with solution of problem, is decided to work out during this project. By enhancing the Quality and
reducing the rejection of casting component which in turn will be profitable for both the industry as
well as the customer is planned in the proposed study.

Keywords: Scanning Electron Microscope, Microstructure of material,

1.INTRODUCTION

IJSER
MATERIAL - Alsi9cu aluminum alloy
Introduction Aluminum matrix composites reinforcement with carbon fibers are perspective engineering materials.
Main advantages of those materials are: high stiffness, specific strength as well as low coefficient of thermal
expansion and high coefficient of thermal and electric conductivity. Potential area of application them could be
aerospace, automotive, and also electronic industry. The aluminum alloys used for composites must have
appropriate strength. The aluminum carbide promotes wetting, but it is brittle and hydrophilic phase, decreases
corrosion resistance and strength of composite materials.

The AC AlSi9CuX series (Al-Si-Cu) casting alloys are widely used for automotive industry. The AC AlSi9CuX
series alloys are used in the production of engine components such as cylinder blocks heads and several parts of car
suspension. The use of aluminum alloy castings in this application is growing, replacing grey iron in many
demanding applications.

2.PROBLEM - Appeared the cracks in component of Alsi9cu alloy during the assembly process. Due to this
casting got rejected at customer end. That condition not suitable for customer is planned and as well as for supplier
company. This analysis is required for find out the causes of crack or failure. By this analysis we confirmed that
cause of crack is extra load applied or process related.

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International Journal of Scientific & Engineering Research, Volume 6, Issue 3, March-2015
ISSN 2229-5518
1531

Crack Area

3. APPROACH

IJSER Cracked surface of samples

In this project we experimentally investigated the cracked surfaces of component. For cracks analysis we
used following methods.

A. Chemical Composition :-

Other aq
ALLOY Si Fe Cu Mn Mg Cr Ni Zn Pb Sn Tih
Each Total Aluminum
8.0- 9.6 2.0- .05-
AlSi9Cu 11.0 -1.2 4.0 0.5 0.55 0.15 0.55 3 0.35 0.15 0.25(0.20) 0.05 0.25 Remainder

Chemical composition report was o.k.

B. Mechanical properties checking

Required hardness > 80 HBW

Actual hardness– 90 HBW -OK

C. Crack failure analysis on SEM (Scanning Electron microscope).

We used to two method for analysis.
 Micrograph of crack surface.
 Microstructure Analysis of samples.

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 International Journal of Scientific & Engineering Research, Volume 6, Issue 3, March-2015
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1532

Micrograph of crack surface:-

In this experiment we analysis the both cracked surface on SEM at 500 X.

Based on these SEM images we try to understand the crack types and properties of crack.

Scanning Electron Microscope (SEM) was used to analyze the cracked surface profile to decide the types
of cracks.

SAMPLE 1

Sample AT 500X Sample AT 500X

Crack

SAMPLE 2
IJSER SEM Images of Sample -1 at 500x and 1000X

Sample AT 500X Sample AT 500X

Dimple and
SEM Images of Sample -2 at 500x and 1000X facets pattern

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International Journal of Scientific & Engineering Research, Volume 6, Issue 3, March-2015
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1533

Crack

Sample AT 500X

Dimple and
facets pattern

SEM Images of Sample -2 at 500X.

Discussion of micrograph

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Faceted fracture surface signifying Brittle pattern. Fracture surface shows dimple and facets pattern. Both
Fracture surface shows internal cracks. The reason for failure may be due to internal cracks

Microstructure Analysis

Scanning Electron Microscope (SEM) was used to analyze micro of the cracked surface . First of all, for
proper testing on SEM these specimens were manually polished and etched by an HF etchant.

MICROSTRUCTURE OF SAMPLES.

SEM image of sample at 500X

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International Journal of Scientific & Engineering Research, Volume 6, Issue 3, March-2015
ISSN 2229-5518
1534

Sample AT 500X

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SEM image of micro porosity

Sample AT 500X

SEM image of micro porosity

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Discussion of microstructure

 Non uniform microstructure.

 Coarse distribution of silicon and CuAl2 in matrix of aluminum.
 Visible surface porosity and oxide inclusions found on sample surface.
 Reference for microstructure: - ASM international handbook.

4. CONCLUSION:-
Extra Load is not responsible for Crack appeared. This Crack failure took place due to manufacturing process
variations. Process parameters variations create the internal cracks, Oxide inclusion and micro porosity on surface.
These defects Leads to crack.

5. SOLUTION:-
We required standardization (optimization) of process parameter for entire cycle of manufacturing. By enhancing
the Quality and reducing the rejection of casting component.

6. ACKNOWLEDGEMENT

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This scientific work is in the period 2014-2015 as a development project headed by Mr. Rajeev Gangwar head of
department of Rico R&D.

Thanks to my colleague Mr. Bhoodev Sharma for support.

References:-

1. J. Gilbert Kaufman - ASM international handbook.

2. L. Bäckerud, G. Chai, Solidification Characteristics of Aluminum Alloys

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