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The Mechanical Properties of Rheo-High Pressure Die Cast Al-Mg-Si-(Cu) 6xxx Series Alloys

Near-net shape casting of wrought aluminium alloys has proven to be difficult due to a tendency towards hot tearing during cooling. Rheo-high pressure die casting (R-HPDC), has been shown to be an effective method of producing near-net shape wrought aluminium alloy castings. Limited information is available regarding the mechanical properties of age-hardenable wrought Al-castings produced by semi-solid metal forming. The purpose of this study is to investigate the effects of chemical composition and natural pre-ageing on the hardness and mechanical properties of rheo-HPDC 6xxx series Al-Mg-Si-(Cu) alloys in the T6 temper condition. The effects of the addition of Cu, as well as the (Mg+Si) content and Mg:Si ratio of the alloys are quantified. Alloys that are included are Cu-free 6004 and 6082, as well as Cu-containing 6013, 6111 and 6066. It is shown that the addition of Cu and excess Si result in higher hardness and strength. Natural pre-ageing has a significant effect (positive for 6004 and negative for the others) on the T6 properties. Good strength values can be achieved, but ductility is dependent on factors such as hot tearing during casting and incipient melting during solution heat treatment.