Fatigue Life and Microstructure after Multiple Remelting of A359 Matrix Composites Reinforced with SiC Particles

The article presents the results of fatigue life tests and microstructure examinations of A359 alloy matrix composites (F3S.10S and F3S.30S) containing 10 and 30wt% of SiC particles, subjected to multiple remelting by conventional gravity casting. Mechanical characteristics were determined in a modified low cycle fatigue (MLCF) test, enabling rapid estimation of fatigue life and other mechanical parameters in practice of any material. Qualitative and quantitative metallographic examinations were also carried out. The quantitative evaluation of microstructure was performed by computer image analysis. A set of geometrical parameters of the reinforcing particles, pores and eutectic precipitates present in the metal matrix was determined. The relationships between the mechanical parameters, structural characteristics and the number of remelting operations were presented. It was found that up to the fourth remelting, the mechanical characteristics, including fatigue life, are slightly deteriorated but decrease gradually in the subsequent operations of remelting. The observed effect is mainly due to the shrinkage porosity occurring as a result of gravity casting. To eliminate this defect, the use of squeeze casting process was recommended. It has also been shown that multiple remelting can be an easy and economically well-founded alternative to other more expensive recycling methods.