Abstract
The precipitation of primary Fe-rich intermetallics (sludge) in AlSi9Cu3(Fe) type alloys has been investigated for different Fe, Mn and Cr contents and cooling rates. Differential scanning calorimetry was used in order to assess the nucleation temperature and the enthalpy of sludge particles as well as to follow their evolution. The results show that the sludge nucleation temperature and the release of latent heat during sludge formation are functions of the initial concentrations of Fe, Mn and Cr in the molten alloy, i.e. the sludge factor, and the cooling rate. Being able to predict the temperature of sludge formation will support the foundries to set the right molten metal temperature in order to prevent sludge precipitation during the entire high-pressure die-casting process.
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