Dedication	5
	Authorship Statement	8
	Bio-sketches	9
	Acknowledgments	12
	Contents	13
	Chapter 1: Al-Si Alloys, Minor, Major, and Impurity Elements	17
	1.1 General Overview: Aluminum Silicon Alloys	17
	1.2 Alloy Designations	19
	1.3 ASTM Standards for Testing AL-SI Castings	19
	1.4 Effect of Main Chemical Constituents of AL-SI Hypereutectic Alloys	20
	1.5 Major Alloying Elements	20
	1.5.1 Silicon	20
	1.5.2 Copper	22
	1.5.3 Nickel	25
	1.5.4 Magnesium	25
	1.5.5 Zinc	26
	1.6 Impurity Elements	26
	1.6.1 Iron	26
	1.6.2 Manganese	27
	References	28
	Chapter 2: Thermal Analysis	32
	2.1 Introduction	32
	2.2 Thermal Analysis Procedure	34
	2.3 Heat Exchange Conditions	34
	2.4 Experimental Results and Thermal Analysis Algorithms	36
	2.5 Applications of the Thermal Analysis Algorithms	44
	2.6 Thermal Analysis, Quench Testing, and Optical Microscopy	49
	2.7 Characterization: Optical and Scanning Electron Microscopy	51
	References	58
	Chapter 3: Metal Casting Process	64
	3.1 Casting Processes: Overview	64
	3.2 High Pressure Die Casting Process	66
	3.3 Lost Foam Process	72
	3.4 Sand Casting and Precision Sand Casting Process	76
	3.5 Aerospace Sand Casting Applications	77
	3.6 Precision Sand for Automotive Applications	81
	3.7 Semi-Permanent Molding Process	83
	3.8 Permanent Mold Process	89
	3.9 Investment Casting Process	91
	3.10 Casting Process Selection	93
	3.11 Heat Treatment Process for Aluminum Castings	94
	References	96
	Chapter 4: Powder Metallurgy	97
	4.1 Introduction to Mechanical Milling	97
	4.2 Al-Si Alloys	99
	4.3 Powder Production Methods	100
	4.4 Mechanical Alloying	102
	4.5 Consolidation Methods	107
	4.6 Sintering	111
	References	120
	Chapter 5: Liquid and Semisolid Melt Treatment: Electromagnetic Stirring	125
	5.1 Introduction to Electromagnetic Stirring	125
	5.2 Electromagnetic Stirring (ES) Principle	126
	5.3 Mechanical and Ultrasonic Stirring	129
	5.4 Electromagnetic Stirring and Vibration	129
	5.5 Discussion of Silicon Modification	138
	References	142
	Chapter 6: Mechanical Properties	147
	6.1 Mechanical Strength and Durability Assessment	148
	6.2 Tensile Testing Properties	148
	6.2.1 Tensile Test Sample Geometries for Casting	152
	6.2.2 Precision Sand with Implemented Chill	152
	6.2.3 Tensile Properties of Casting Sections Where Cylindrical Samples Are Not Possible	154
	6.3 Weibull Statistical Method for Treating Tensile Test Data	157
	6.3.1 Examples of Weibull Statics Used in Aluminum Castings	158
	6.4 Fatigue Durability of Aluminum Castings	162
	6.4.1 Fatigue Staircase Generation for Al-Si Castings	167
	6.5 Weld Repair of Aluminum Castings	171
	References	175
	Chapter 7: Applications in the Automotive and Aerospace Industries	177
	7.1 Aluminum Alloys: A Brief History	177
	7.2 Casting Quality Requirements	179
	7.3 Applications of Aluminum Castings in Automotive and Aerospace Industries	181
	7.4 Impact of Aluminum Cost on Casting Processes	184
	7.5 Aerospace	184
	7.6 Automotive	184
	References	185
	Chapter 8: Principles of Solidification	186
	8.1 Aluminum Alloy Systems	186
	8.2 Alloy Designations	188
	8.3 Solidification Sequence of Al-Si Alloys	190
	8.4 Primary-Phase Evolution: ?-Al Dendritic Structure	191
	8.4.1 Effect of Silicon Concentrations	195
	8.4.2 Effect of Iron Concentrations	197
	8.4.3 Effect of Copper Concentrations	200
	8.4.4 Effect of Magnesium Concentration	201
	8.4.5 Si Eutectic Modifiers: Strontium, Antimony, and Sodium	202
	8.4.6 Grain Refinement	203
	8.5 Mechanism for Pore Development	204
	8.6 Hydrogen Concentrations: Measurement and Established Thresholds	206
	8.7 Methods of Hydrogen Absorption	208
	8.8 Kinetics for Oxide Generation	210
	8.9 Titanium Boride (TiB2) Inclusions	211
	8.10 Strontium-Based Inclusions	212
	8.11 Reduced Pressure Test Methodology	212
	8.12 Methods for Degassing	218
	References	221
	Chapter 9: Grain Refinement	224
	9.1 Introduction to Grain Refinement	224
	9.2 Chemical Grain Refinement	225
	9.2.1 Principles and Grain Growth Restriction Factor	225
	9.2.2 Grain Refinement of Aluminum-Rich Phases	226
	9.3 Silicon in Liquid and Semisolid States	228
	9.3.1 Structure in the Liquid State	228
	9.3.2 Al-Si Hypereutectic Alloys	228
	9.3.3 Primary Si Growth	233
	9.4 Silicon Modification Methods	235
	9.4.1 Chemical Modification of Si Rich Phases	235
	9.4.2 Thermal Modification	238
	9.4.3 Mechanical Modification	240
	References	241
	Erratum to: Al-Si Alloys: Automotive, Aeronautical, and Aerospace ApplicationsFrancisco C. Robles Hernandez, Jose Martin Herrera Ramírez, and Robert Mackay	248
	Index	249