Rapid investment casting of nanotechnology-enhanced aluminum alloy 6061

Purpose High-performance wrought aluminum alloys, particularly AA6061, are pivotal in industries like automotive and aerospace due to their exceptional strength and good response to heat treatments. Investment casting offers precision manufacturing for these alloys, because casting AA6061 poses challenges like hot cracking and severe shrinkage during solidification. This study aims to address these issues, enabling crack-free investment casting of AA6061, thereby unlocking the full potential of investment casting for high-performance aluminum alloy components. Design/methodology/approach Nanotechnology is used to enhance the investment casting process, incorporating a small volume fraction of nanoparticles into the alloy melt. The focus is on widely used aluminum alloy 6061, utilizing rapid investment casting (RIC) for both pure AA6061 and nanotechnology-enhanced AA6061. Microstructural characterization involved X-ray diffraction, optical microscopy, scanning electron microscopy, differential scanning calorimetry and energy dispersive X-ray spectroscopy. Mechanical properties were evaluated through microhardness and tensile testing. Findings The study reveals the success of nanotechnology-enabled investment casting in traditionally challenging wrought aluminum alloys like AA6061. Achieving crack-free casting, enhanced grain morphology and superior mechanical properties, because the nanoparticles control grain sizes and phase growth, overcoming traditional challenges associated with low cooling rates. This breakthrough underscores nanotechnology's transformative impact on the mechanical integrity and casting quality of high-performance aluminum alloys. Originality/value This research contributes originality and value by successfully addressing the struggles in investment casting AA6061. The novel nano-treating approach overcomes solidification defects, showcasing the potential of integrating nanotechnology into rapid investment casting. By mitigating challenges in casting high-performance aluminum alloys, this study paves the way for advancements in manufacturing crack-free, high-quality aluminum alloy components, emphasizing nanotechnology's transformative role in precision casting.