Abstract: The present invention discloses a method for optimizing heat treatment of precipitation-hardened alloys having at least one precipitate phase by decreasing aging time and/or aging temperature using thermal growth predictions based on a quantitative model. The method includes predicting three values: a volume change in the precipitation-hardened alloy due to transformations in at least one precipitation phase, an equilibrium phase fraction of at least one precipitation phase, and a kinetic growth coefficient of at least one precipitation phase. Based on these three values and a thermal growth model, the method predicts thermal growth in a precipitation-hardened alloy. The thermal growth model is particularly suitable for Al—Si—Cu alloys used in aluminum alloy components. The present invention also discloses a method to predict heat treatment aging time and temperature necessary for dimensional stability without the need for inexact and costly trial and error measurements.

Abstract: The present invention discloses a method for optimizing heat treatment of precipitation-hardened alloys having at least one precipitate phase by decreasing aging time and/or aging temperature using thermal growth predictions based on a quantitative model. The method includes predicting three values: a volume change in the precipitation-hardened alloy due to transformations in at least one precipitation phase, an equilibrium phase fraction of at least one precipitation phase, and a kinetic growth coefficient of at least one precipitation phase. Based on these three values and a thermal growth model, the method predicts thermal growth in a precipitation-hardened alloy. The thermal growth model is particularly suitable for Al-Si-Cu alloys used in aluminum alloy components. The present invention also discloses a method to predict heat treatment aging time and temperature necessary for dimensional stability without the need for inexact and costly trial and error measurements.

Abstract: A method for quantitatively predicting and consequently minimizing the amount of critical phases such as eutectic Al2Cu formed during solidification of Al—Si—Cu alloys used in a vehicle engine component comprises developing a micromodel to simulate microstructure evolution in cast Al—Si or Al—Cu alloys. The micromodel is calibrated using experimental thermal analysis cooling curves and an optimization process. Microstructure evolution and cooling curves are simulated for a casting using the calibrated micromodel. Precipitation of critical phases such as Al2Cu in the casting is predicted as a function of solidification conditions. The model allows casting process variables to be varied with predictable results so that the casting process can be controlled via the micromodel.