Abstract
An aluminum alloy containing 4% Ca, ~ 1% Fe, ~ 0.6% Si, ~ 0.2% Zr, and ~ 0.1% Sc (wt.%) was manufactured in the form of a 150-mm-diameter × 800-mm-long cylindrical ingot. It is shown that this model alloy has high manufacturability both for the casting of industrial-sized ingots and for rolling or drawing. This is due to the combination of a narrow temperature range of solidification (~ 20°C) and a favorable morphology for the (Al) + Al4Ca + Al10CaFe2 + Al2CaSi2 quaternary eutectic, which has a fine structure and a total content of eutectic phases above 18 vol.%. The high manufacturability of the alloy allows its use for the fabrication of various wrought semi-finished products with a balanced combination of mechanical and physical properties. Compared to other Al-based composite alloys, the Al-Ca alloy has a lower density (2.65 g/cm3), lower cost due to the possibility of using recycled charges (i.e., with higher iron and silicon contents) for their production, and can be further strengthened by L12 type nanoprecipitates.
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