Morphology and mechanical properties of melt-spun and conventionally cast aluminium, AlMg and AlSi alloys before and after hot extrusion

Abstract

Rapidly solidified aluminium, AlMg (0 to 16.5 at % Mg) and AlSi (0 to 20.2 at % Si) alloys were produced by melt spinning. The AlMg ribbons were single-phase, whereas the AlSi ribbons were dual-phase. In the ribbons of both alloy systems the fineness of the microstructure increased with increasing alloying element content. The melt-spun ribbons were consolidated by hot extrusion. For comparison, conventionally cast alloys of corresponding compositions were extruded analogously. During the extrusion process in AlMg (16.5 at % Mg) and in the AlSi alloys precipitation occurred. The consolidation of the ribbons was markedly influenced by the oxide layer on the ribbon surfaces: in the AlSi consolidates a more intimate contact between the ribbons was apparent than in the aluminium and AlMg consolidates. In the extrudates of the conventionally cast alloys the grains and second-phase particles were much larger than in the consolidates. The observed dependence on alloy composition of hardness, ultimate tensile strength and elongation at fracture of both consolidated ribbons and extrudates of the conventionally cast alloys are discussed in terms of matrix grain size, solute content of the matrix, amount and size of second-phase particles and recrystallization behaviour. For all compositions of the alloys the Vickers hardness of the as-melt-spun ribbons was higher than that of the consolidated products, owing to recrystallization and precipitation provoked by the hot consolidation process. The ultimate tensile strength as well as the elongation at fracture of both consolidated ribbons and extruded conventionally cast alloys did not differ significantly for AlMg. However, due to a finer microstructure and a stronger inter-ribbon bonding, for AlSi alloys with a high silicon content the rapid solidification processing route did yield a product with significantly improved mechanical properties as compared with the extruded conventionally cast alloys.