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<p>In this study, the method combining numerical simulation with experimental verification was adopted to investigate the influence laws of pouring temperature (650~680&#xa0;°C) and casting–forging interval time (3~12 s) on the initial solid fraction distribution during forging, microstructure evolution, formation of casting defects, and mechanical properties of Al-Cu alloy, and the intrinsic correlation mechanism between process parameters and alloy properties was clarified. By means of density measurement, X-ray non-destructive testing, metallographic microscopic observation, scanning electron microscopy (SEM) analysis, and mechanical property testing, the microstructural and performance characteristics of the alloy under different process parameters were systematically characterized. The results show that the pouring temperature exerts a significant influence on the alloy forming quality by regulating the distribution of the initial solid fraction during forging, and the casting–forging interval time determines the solidification state of the alloy at the time of forging intervention. When the pouring temperature is 660&#xa0;°C, 56.3% of the alloy melt has a solid fraction in the range of 35% to 65%. Under this condition, forging can effectively break the dendrite arms and refine the grain size, avoiding the linear segregation at low pouring temperatures and the porosity and shrinkage cavity defects at high pouring temperatures. When the casting–forging interval time is 6s, 56.3% of the alloy melt has a solid fraction in the range of 35% to 65%. Forging can fully facilitate melt feeding and microstructure densification, and effectively inhibit defects such as shrinkage cavities and segregation. The optimal process parameters determined in this study are a pouring temperature of 660&#xa0;°C and a casting–forging interval time of 6 s. After T6 heat treatment, the Al-Cu alloy prepared under such conditions features a uniform and dense microstructure with the grain size refined to 151.98 μm, without obvious linear segregation, porosity and shrinkage cavity defects. It attains the optimal comprehensive mechanical properties, with the hardness, tensile strength, and elongation reaching 74.2 HV, 441 Mpa, and 4.7%, respectively.</p>

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Effects of Pouring Temperature and Casting–Forging Interval on the Microstructure and Mechanical Properties of Integrally Cast–Forged Al-Cu Alloy

  • 期刊论文

  • 发表日期：

    2026年5月6日

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  • Chenxi Ma,
  • Peng Shen,
  • Jiahao Gao,
  • Jingman Xu

摘要

In this study, the method combining numerical simulation with experimental verification was adopted to investigate the influence laws of pouring temperature (650~680 °C) and casting–forging interval time (3~12 s) on the initial solid fraction distribution during forging, microstructure evolution, formation of casting defects, and mechanical properties of Al-Cu alloy, and the intrinsic correlation mechanism between process parameters and alloy properties was clarified. By means of density measurement, X-ray non-destructive testing, metallographic microscopic observation, scanning electron microscopy (SEM) analysis, and mechanical property testing, the microstructural and performance characteristics of the alloy under different process parameters were systematically characterized. The results show that the pouring temperature exerts a significant influence on the alloy forming quality by regulating the distribution of the initial solid fraction during forging, and the casting–forging interval time determines the solidification state of the alloy at the time of forging intervention. When the pouring temperature is 660 °C, 56.3% of the alloy melt has a solid fraction in the range of 35% to 65%. Under this condition, forging can effectively break the dendrite arms and refine the grain size, avoiding the linear segregation at low pouring temperatures and the porosity and shrinkage cavity defects at high pouring temperatures. When the casting–forging interval time is 6s, 56.3% of the alloy melt has a solid fraction in the range of 35% to 65%. Forging can fully facilitate melt feeding and microstructure densification, and effectively inhibit defects such as shrinkage cavities and segregation. The optimal process parameters determined in this study are a pouring temperature of 660 °C and a casting–forging interval time of 6 s. After T6 heat treatment, the Al-Cu alloy prepared under such conditions features a uniform and dense microstructure with the grain size refined to 151.98 μm, without obvious linear segregation, porosity and shrinkage cavity defects. It attains the optimal comprehensive mechanical properties, with the hardness, tensile strength, and elongation reaching 74.2 HV, 441 Mpa, and 4.7%, respectively.