Abstract
Formation of the fir-tree structure in DC cast 5005 alloy was studied by means of Xray-diffraction and optical microscopy comparing with that of Al-Fe-Si alloy (1100). Unidirectional solidification experiments and direct measurements of cooling rate during solidification in DC casting process were also made. The main intermetallic compounds in the outer and inner regions of fir-tree structure in DC cast 1100 alloy are respectively Al3Fe and Al6Fe as shown in the previous works. The major phase AlmFe is found in the outer region in 5005 alloy and Al6Fe and Al3Fe in the inner region. A clearly shaded boundary lies between AlmFe and Al6Fe (or Al6Fe + Al3Fe) phase regions in the ingot of each alloy unidirectionally solidified. The cooling rate at the boundary(the minimum cooling rate for AlmFe formation, Vc) in 5005 alloy is smaller than those in Al-0.5%Fe and 1100 alloys, and is in the range of cooling rate in DC castings. The fir-tree structure of AlmFe is formed when cooling rate near the surface of DC cast 5005 alloy exceeds Vc.
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