SAE TECHNICAL PAPERSERIES 970019 The Effect ofSolidification Time ontheMechanical Properties ina Cast A356-T6 Aluminum Alloy James M.Boileau, Jacob W.Zindel, andJohn E.Allison Ford Motor Company Scientific Research Lab. Reprinted from: Applications forAluminum inVehicle Design (SP-1251) International Congress &Exposition Detroit,MichiganFebruary 24-27, 1997 400Commonwealth Drive, Warrendale, PA15096-0001 U.S.A. Tel:(412)776-4841 Fax:(412)776-5760 Detroit,Downloaded from SAE International by University of Birmingham, Monday, August 20, 2018The appearanceofthe ISSN codeatthe bottomofthispage indicatesSAE's consentthat copies ofthe papermaybe made forpersonal orinternaluseofspecificclients.Thisconsent isgiven onthecondition however,that thecopier paya$7.00perarticlecopyfeethrough theCopyright Clearance Center, Inc.Operations Center, 222Rosewood Drive, Danvers, MA01923 forcopying beyond thatpermitted bySections 107or108ofthe U.S.Copyright Law. Thisconsent doesnotextend other kindsof copyingsuch ascopyingforgeneral distribution, foradvertising orpromotional purposes, for creatingnew collective works,or forresale. SAE routinely stocks printed papers foraperiod ofthree years following date ofpublication. Direct yourorders toSAECustomerSalesandSatisfactionDepartment. Quantity reprint ratescanbeobtained fromtheCustomer Sales andSatisfaction Depart ment Torequest permission toreprint atechnicalpaper orpermissionto usecopyrightedSAE publications inother works, contact theSAEPublications Group. Nopartofthispublication maybyreproduced inanyform, inanelectronic retrieval systemor otherwise, withoutthe prior writtenpermissionofthepublisher. ISSN 0148-7191 Copyright 1997 Society ofAutomotive Engineers, Inc. Positions andopinions advanced inthispaper arethoseoftheauthor(s)andnotnecessarily thoseofSAE. Theauthor issolelyresponsibleforthecontentofthepaper.Aprocessis available bywhich discussions willbeprinted withthepaper ifitispublished inSAE Transactions. Forpermission topublish thispaper infullorinpart,contact theSAE Publications Group.Persons wishingtosubmitpaperstobeconsideredforpresentationorpublicationthrough SAEshould send themanuscript ora300word abstract ofaproposed manuscript to: Secretary, Engineering Meetings Board, SAE. Printed inUSA Downloaded from SAE International by University of Birmingham, Monday, August 20, 2018970019 The Effect ofSolidification Time ontheMechanical Properties ina Cast A356-T6 Aluminum Alloy James M.Boileau, Jacob W.Zindel, andJohn E.Allison Ford Motor Company Scientific Research Lab. Copyright 1997 Society ofAutomotive Engineers, Inc. ABSTRACT Astudy was conducted todetermine how the mechanical properties ofanA356-T6 Aluminum alloy areaffected bysolidification time. Solidification time has been found tohave alarge effect onthe microstructure, especially interms ofthesizeofthe SDAS aswell asthesizeanddistribution ofporosity. Solidification time also has alarge effect onthe ultimate tensile strength, ductility, and fatigue properties ofA356-T6 Al. Comparisons between porosity-containing ("As-Cast) andporosity-free ("As Cast +HIP") samples revealed thatthepresence of porosity hadadramatic effect onfatigue life; tensile properties remained unaffected. INTRODUCTION Worldwide, the use of cast aluminum components inautomotive applications isincreasing. Cast aluminum components areallowing theindustry to meet current aswell asfuture customer andlegislative expectations (such asreduced weight andincreased fuel economy) while maintaining current vehicle size and performance. Asanexample, aV8engine block cast inaluminum weighs approximately 32kg.(70lbs.), compared to68kg.(150 lbs.) ingrey castiron. Todate, castaluminum components have been primarily used inengine components, including blocks, cylinder heads, pistons, intake manifolds, brackets, and housings. However, asthedemand forreduced weight andlower unsprung mass hasincreased, strong interest hasbeen generated inusing castaluminum forchassis andsuspension system