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<p>The increasing demand for high-performance cast components has led to the development of semi-solid casting techniques. One such method, known as the strain-induced melt activation (SIMA) process, is a cost-effective approach that is becoming increasingly important for creating lightweight components in high-performance structural applications. The SIMA process yields a homogeneous structure with minimal casting defects, significantly enhancing the ultimate tensile strength (UTS, measured in MPa) and total elongation (El, in percentage) of the Al-7Si alloy. Key process parameters, including pre-deformation, isothermal temperature, and holding time, were optimized using response surface methodology. An analysis of the ANOVA results confirms that pre-deformation is the most influential factor, followed by isothermal temperature and holding time. The optimized parameters of the M-SIMA process were applied to experimental investigation and validated. This method modifies the traditional dendrite structure into equiaxed spherical primary α-Al grains, which are surrounded by finer eutectic silicon particles. Additionally, casting flaws such as porosity and shrinkage are minimized. As a result, the tensile strength and elongation of the SIMA-processed alloy improved by 74% and 88%, respectively, compared to conventional cast alloy.</p>

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Experimental Design to Optimize the Input Variables for Modified Strain-Induced Melt Activation Process to Achieve High Mechanical Performance of Hypoeutectic Al-Si Alloy

  • 期刊论文

  • 发表日期：

    2026年2月21日

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  • Anand Kumbhare,
  • Anil Bisen,
  • Palash Poddar,
  • Kanai Lal Sahoo,
  • Durbadal Mandal,
  • Chandan Choudhary

摘要

The increasing demand for high-performance cast components has led to the development of semi-solid casting techniques. One such method, known as the strain-induced melt activation (SIMA) process, is a cost-effective approach that is becoming increasingly important for creating lightweight components in high-performance structural applications. The SIMA process yields a homogeneous structure with minimal casting defects, significantly enhancing the ultimate tensile strength (UTS, measured in MPa) and total elongation (El, in percentage) of the Al-7Si alloy. Key process parameters, including pre-deformation, isothermal temperature, and holding time, were optimized using response surface methodology. An analysis of the ANOVA results confirms that pre-deformation is the most influential factor, followed by isothermal temperature and holding time. The optimized parameters of the M-SIMA process were applied to experimental investigation and validated. This method modifies the traditional dendrite structure into equiaxed spherical primary α-Al grains, which are surrounded by finer eutectic silicon particles. Additionally, casting flaws such as porosity and shrinkage are minimized. As a result, the tensile strength and elongation of the SIMA-processed alloy improved by 74% and 88%, respectively, compared to conventional cast alloy.