Abstract
Abstract The evolution of iron (Fe) bearing intermetallics (Fe-IMCs) during direct chill casting and homogenization of a grain-refined 6063 aluminum-magnesium-silicon (Al-Mg-Si) alloy has been studied. The as-cast and homogenized microstructure contained Fe-IMCs at the grain boundaries and within Al grains. The primary α-Al grain size, α-Al dendritic arm spacing, IMC particle size, and IMC three-dimensional (3D) inter-connectivity increased from the edge to the center of the as-cast billet; both α c-AlFeSi and β-AlFeSi Fe-IMCs were identified, and overall α c-AlFeSi was predominant. For the first time in industrial billets, the different Fe-rich IMCs have been characterized into types based on their 3D chemistry and morphology. Additionally, the role of β-AlFeSi in nucleating Mg2Si particles has been identified. After homogenization, α c-AlFeSi predominated across the entire billet cross section, with marked changes in the 3D morphology and strong reductions in inter-connectivity, both supporting a recovery in alloy ductility.
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