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Abstract
Powder metallurgy allows for the rapid, automated and efficient production of many different types of automotive components. However, a drawback is the limited selection of readily available light alloy blends. Owing to the wide spread use of aluminium–silicon casting alloys for existing components it is logical to develop aluminium–silicon PM options. Therefore, an experimental hypoeutectic aluminium–silicon alloy was chosen for study and an optimum processing route developed. Tests were performed to determine the green strength and density as a function of compaction pressure. Sintering conditions were optimised based on sintered density, hardness and dimensional changes. Metallography, differential scanning calorimetry and energy dispersive X-ray spectroscopy analysis provided insight into post-sinter furnace cooling and heat treatment parameters. An appropriate T6 heat treatment was developed and samples were tested in tension. The alloy was able to achieve a high sintered density approaching 98% and a yield strength of 232 MPa under the T6 condition.
The authors would like to acknowledge Natural Sciences and Engineering Research Council of Canada (NSERC/CRSNG) for funding via the strategic grant no. 350505-07, and ECKA Granules (Fürth, Germany) for the provision of all metal powders utilised. Special thanks are also extended to Patricia Scallion, Brad Collier, Christopher Boland, David Walker, Ryan Mann and David Heard for their assistance and guidance in the laboratory.