Integrated property predictions during casting and heat treatment of Al-Si-Cu-Mg alloys by precipitation simulation

Abstract The production and manufacture of aluminium castings typically involves multiple heat treatment process steps. Simulation tools are very useful to help predict the evolution of mechanical properties, to improve process parameters and as a guideline for casting design. In this study, a kinetic model, based on Nucleation and Growth Theory (CNGT), was developed and implemented for modelling heat treatment in a casting process simulation tool. Starting from information generated from the simulation of solidification and cooling of the casting, simulation was carried out to predict further precipitation behaviour of multiple Cu or Mg-Si -containing phases during solution treatment, quenching, and artificial ageing processes in heat treatment of Al alloys. Model validation was carried out within the research cluster “Advance Metals and Processes” in Aachen, Germany. Heat treatments were performed on two different Al-Si-Cu-Mg alloys with different quench methods and at different ageing temperatures. Experimental investigations including atom probe, wavelength dispersive X-ray spectroscopy, and tensile tests were conducted to calibrate and validate the model. The simulations showed good agreement for the studied conditions and a promising modelling approach for integrated simulation of casting and heat treatment for industrial applications.