Abstract
Abstract The present study was carried out to investigate the effects of Ni, Mn, Zr, and Sc additions, individually or in combination, on the microstructure of 354 casting alloy (Al-9 wt.% Si-1.8 wt.% Cu-0.5 wt.% Mg). Microstructural examination and thermal analysis data showed that the main reactions detected during the solidification of the six 354 alloys (G1, G6–G10) investigated are: formation of the α-Al dendritic network; precipitation of Al-Si eutectic and post-eutectic β-Al5FeSi; Mg2Si phase; transformation of the β-phase into π-Al8Mg3FeSi6 phase; and precipitation of Al2Cu and Q-Al5Mg8Cu2Si6 phases. With 2 wt.% Ni addition, the formation of Al9FeNi and Al3CuNi phases is observed. In the base 354 alloy the main phases are restricted to Cu-, Mg-, and Fe-rich intermetallic phases. The Si particle characteristics and volume fraction of intermetallics are influenced by the solidification rate and Mg level, whereas addition of Fe and/or Mn has no significant influence. In alloy G9, Fe, Mn and Ni interact to form new intermetallic phases. An increased Fe content leads to formation of polyhedral/star-like sludge particles in addition to α-Fe and β-Al5FeSi phases; the presence of the hard sludge particles within the soft α-Al dendrites improves the alloy properties.
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