Abstract
In the present study, the effect of the primary processing route on the microstructural variation and heat-treatment response of a commercial AlSi alloy (designated as A390) is investigated. The AlSi alloy selected for the present investigation was processed using conventional casting and spray atomization and deposition routes. Microscopic investigation carried out on the as-spray deposited samples revealed that the secondary phases such as silicon were at least an order of magnitude finer than that observed in the as-cast samples. In addition, as-spray deposited material revealed a considerable spheroidization of the secondary phases in the matrix as compared to the needle-shaped morphology exhibited by the as-cast material. The results of the heat-treatment studies indicated a faster solutionizing kinetics (dissolution) and a similar aging (precipitation) response of spray-deposited samples when compared to the cast samples. The correlation between the microstructural characteristics and the heat-treatment behavior of the cast and spray processed samples are discussed, taking into account the solidification conditions present during the respective processing techniques.
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