Abstract
The influence of Fe content on the three-dimensional (3D) morphologies of Fe-rich intermetallic phases (Fe phases), Al2Cu, and pores and mechanical properties of cast Al-5.0Cu-0.6Mn alloys with 0.5 and 1.0 wt % Fe are characterized using synchrotron X-ray tomography and a tensile test. The results show that both Fe phases and Al2Cu exhibit a complex 3D network structure, and the pores are irregular with complex interconnected and near-globular shape. As the Fe content increases from 0.5% to 1.0%, the volume fraction and equivalent diameter of Fe phases increase, whereas both their interconnectivities decrease. Skeletonization analysis shows that the Chinese-script-shaped Fe phase is more compacted than the plate-like Fe phases. The equivalent diameter and sphericity of pores vary with Fe content, and their relationships follow exponential functions. The addition of Fe results in a decrease in the ultimate tensile strength and elongation from 224 MPa to 200 MPa and from 5.5% to 3.6%, respectively, owing to increasing volume fraction of sharp-edged Fe phases and pores, resulting in stress concentration during tensile test.
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