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<p>Targeting quality control requirements for 6082 aluminum alloy billets used in automotive precision forgings, this study systematically investigated the influence of drawing speed (180-240&#xa0;mm/min) on microstructural homogeneity and mechanical properties of Φ70-mm small-diameter horizontal direct-chill cast billets. Experimental results reveal significant positional dependence in grain size and secondary phase distribution, characterized by coarse grains in upper/lower regions (106.86-134.01&#xa0;μm) coexisting with refined grains in the central region (92.44-115.85&#xa0;μm). At 210&#xa0;mm/min, minimal grain size variation (15.09&#xa0;μm range) and optimized cooling rates (39.0-74.2&#xa0;K/s) were achieved, reducing β-Al(Fe,Mn)Si phase fraction differential to 0.6% while promoting β → α transformation toward equilibrium α-Al(Fe,Mn)Si. Mechanical testing confirms superior property homogeneity at 210&#xa0;mm/min: tensile strengths of 260.4&#xa0;MPa (upper), 267.4&#xa0;MPa (central), and 248.3&#xa0;MPa (lower) with merely 4.4 HV 0.1 hardness variation. Under high-speed conditions (240&#xa0;mm/min), however, the central region cooling rate plummets to 30.5&#xa0;K/s, inducing β-phase coarsening (twofold size increase) and exacerbating central-lower strength differential to 42.6&#xa0;MPa. This work establishes 210&#xa0;mm/min as the optimal processing window for small-diameter billets, providing theoretical foundations for high-performance precision forgings like automotive control arms.</p>

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Effect of Casting Speed on the Microstructure and Properties of Horizontally Direct-Chill Cast 6082 Aluminum Alloy

  • 期刊论文

  • 发表日期：

    2026年2月4日

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  • Wei Xu,
  • Zhimin Liu,
  • Shuang-yong Tian,
  • Zhi-hao Zhao,
  • Zhen Xu

摘要

Targeting quality control requirements for 6082 aluminum alloy billets used in automotive precision forgings, this study systematically investigated the influence of drawing speed (180-240 mm/min) on microstructural homogeneity and mechanical properties of Φ70-mm small-diameter horizontal direct-chill cast billets. Experimental results reveal significant positional dependence in grain size and secondary phase distribution, characterized by coarse grains in upper/lower regions (106.86-134.01 μm) coexisting with refined grains in the central region (92.44-115.85 μm). At 210 mm/min, minimal grain size variation (15.09 μm range) and optimized cooling rates (39.0-74.2 K/s) were achieved, reducing β-Al(Fe,Mn)Si phase fraction differential to 0.6% while promoting β → α transformation toward equilibrium α-Al(Fe,Mn)Si. Mechanical testing confirms superior property homogeneity at 210 mm/min: tensile strengths of 260.4 MPa (upper), 267.4 MPa (central), and 248.3 MPa (lower) with merely 4.4 HV 0.1 hardness variation. Under high-speed conditions (240 mm/min), however, the central region cooling rate plummets to 30.5 K/s, inducing β-phase coarsening (twofold size increase) and exacerbating central-lower strength differential to 42.6 MPa. This work establishes 210 mm/min as the optimal processing window for small-diameter billets, providing theoretical foundations for high-performance precision forgings like automotive control arms.