Al-Si Alloys Research Articles

Processing and properties of Al–Si microcapsules with a biomimetic-corrugated structure and corundum-mullite composite shell

The encapsulation of metal-based phase change materials using ceramics can realize safe and effective storage of high-temperature thermal energy. However, the use of a low toughness ceramic shell around the microcapsules cannot ensure the provision of a high latent heat and thermal cyclic stability. Here, we provide a new and effective design strategy for preparing biomimetic Al–Si microcapsules that are based on a sea-shell corrugated structure and a nano-scale corundum-mullite composite shell. The latent heat of the microcapsules was over 400 J/g, much greater than other metal-based microcapsules reported to date. The unique biomimetic-corrugated structure microcapsules obtained by a heat treatment at 1000 °C exhibited excellent thermal stability, achieving near zero heat loss after 5000 thermal cycles, whose latent heat of absorption and release reached up to 448.3 J/g and 451.8 J/g respectively. Furthermore, the microcapsules possessed a giant heat storage density of 945.8 J/g within 300–700 °C, and the performance figure of merit was 6384.2 × 106 J2·K–1·s–1·m–4, approximately 15 times higher than that of commercial solar salt. This new approach provides a pathway the practical application of Al–Si alloys as thermal storage materials for renewable energy applications.

Microstructure and properties of SiC ceramic-modified aluminium alloy fabricated using wire arc additive manufacturing

A method for improving the properties of the deposited metal in wire arc additive manufacturing of Al–Si alloy is proposed here, which introduces SiC ceramic particles into the side-axis wire feed. The effects of SiC ceramic particles on the macroscopic morphology, microstructure and mechanical properties, corrosion resistance, and wear resistance of deposited metals were studied. The results show that the introduction of SiC particles will not affect the surface-forming quality of the deposited metal; this is likely due to the stable droplet transfer and no splashing. The transverse and longitudinal tensile strengths are increased by 10.1 % and 11.3 %, respectively, while the corresponding elongations are increased by 33.1 % and 47.2 %, respectively. Further, the corrosion resistance and wear resistance of Al–Si alloy deposited metals containing SiC are improved. The (100) base surface has strong texture characteristics along the deposition direction X0, and the maximum polar density decreases to 13.63, which indicates that SiC promotes the transformation of columnar crystals to equiaxial crystals. The interface between SiC and Al is non-coherent, and the performance improvement lies in the enhanced dispersion distribution and load transfer of SiC. A ring structure was prepared using double-wire arc additive manufacturing technology, and the feasibility of side-axis wire feeding technology was verified.

Development of Low-Pressure Die-Cast Al-Zn-Mg-Cu Alloy Propellers-Part Ⅰ: Hot Tearing Simulations for Alloy Optimization.

Recent advances in the leisure boat industry have spurred demand for improved materials for propeller manufacturing, particularly high-strength aluminum alloys. While traditional Al-Si alloys like A356 are commonly used due to their excellent castability, they have limited mechanical properties. In contrast, 7xxx series alloys (Al-Zn-Mg-Cu based) offer superior mechanical characteristics but present significant casting challenges, including hot-tearing susceptibility (HTS). This study investigates the optimization of 7xxx series aluminum alloys for low-pressure die-casting (LPDC) processes to enhance propeller performance and durability. Using a constrained rod-casting (CRC) method and finite element simulations, we evaluated the HTS of various alloy compositions. The results indicate that increasing Zn and Cu contents generally increase HTS, while a sufficient Mg content of 2 wt.% mitigates this effect. Two optimized quaternary Al-Zn-Mg-Cu alloys with relatively low HTS were selected for LPDC propeller production. Simulation and experimental results demonstrated the effectiveness of the proposed alloy compositions, highlighting the need for further process optimization to prevent hot tearing in high Mg and Cu content alloys.

Coral-shaped AlSi anode materials for Li-ion batteries enabled by THF-based electrolyte

This research aims to implement a strategy of using a controlled acidic etching on AlSi alloy particles to partially remove Al and preserve a porous Si framework as anode materials. The etched AlSi materials with different Al/Si weight ratios have been investigated in lithium-ion batteries. Microstructural analysis shows the evolution of the AlSi material during selective wet etching, highlighting the preservation of coral-shaped Si nanostructures with an Al-rich core. Lower Al/Si ratios result in increased surface area and pore volume, which is favorable for improving lithium-ion diffusion and accommodating volume expansion during cycling. Evaluation of electrochemical performance in different electrolytes proves the importance of electrolyte selection for AlSi anodes. The tetrahydrofuran-based (THF-based) electrolyte stabilizes electrochemical reactions, resulting in superior specific capacity, cycle life, and Coulombic efficiency compared to the carbonate-based electrolyte with fluoroethylene carbonate additive. Rate performance analysis shows excellent high-rate capability with stable capacity retention at 3C, particularly in Al53Si47 and Al10Si90 materials. Electrochemical impedance spectroscopy measurements emphasize the critical role of porous structure and electrolytes in sustaining low resistance and enhancing cycle life performance. Selective aluminum etching and the THF-based electrolyte effectively mitigate the breakdown and subsequent reformation of the solid electrolyte interphase, resulting in superior efficiency and extended lifespan.

Microstructural and Electrochemical Study: Pitting Corrosion Mechanism on A390 Al-Si Alloy and Ce-Mo Treatment as a Better Corrosion Protection.

Sulfuric acid anodizing assisted by a hydrothermal sealing with inhibitors [Ce3+-Mo6+] was used to prevent pitting corrosion on spray-deposited hypereutectic Al-Si alloy (A390). An investigation concerning the evaluation of pitting corrosion resistance on the anodic oxide thin film with ions incorporated was carried out in NaCl solution using electrochemical measurements (i.e., potentiodynamic polarization and electrochemical impedance spectroscopy, EIS). The influence of Si phase morphology and size on the growth mechanism of an anodic oxide film was characterized by scanning electron microscopy (SEM) and X-ray diffraction (XRD). The results were then compared with those for its equivalent IM390 alloy (Al-17Si-4.5Cu-0.6Mg) produced through a conventional process ingot metallurgy, IM. The electrochemical findings indicate that sulfuric acid anodizing followed by a simple hot water sealing treatment was ineffective. In this manner, an intense attack was localized by pitting corrosion that occurred on the anodic oxide film in less than three days, as denoted by characteristic changes in the EIS spectra at the lowest frequencies. Improved results were achieved for Ce-Mo surface modification, which can provide better corrosion resistance on the aluminum alloys because no signs of pits were observed during the corrosion testing.

Microstructure and mechanical properties of non-heat-treated Al–8Si-0.2Mg-0.5Mn alloy inoculated by Al–Nb–B refiner

Al–Nb–B refiner has been considered as an alternative to Al–Ti–B refiner for hypoeutectic Al–Si alloys due to Si-poisoning effect. In this paper, the effects of Al–Nb–B and Al–Ti–B refiner on the microstructure and mechanical properties in indirect squeeze casting Al–8Si-0.2Mg-0.5Mn alloy were compared. Results show that the grain sizes in the edge chilling layer, segregation band, and the center region of the Al–Nb–B refined alloys were refined by 13.9%, 12.5%, and 17.6% compared to Al–Ti–B refined alloys, respectively. The yield strength, tensile strength, and elongation of Al–Nb–B inoculated alloys were superior to those of the unrefined alloys and Al–Ti–B inoculated alloys. The coexistence of NbAl3 and NbB2 particles in the Al–Nb–B refiner exhibited excellent anti Si-poisoning capability. They significantly decreased the grain size and uniformly distributed the eutectic Si particles and Fe-rich phases, resulting in an increase in the yield strength of the alloy by 16.1% compared to the Al–Ti–B inoculated alloy. The distribution of iron-rich phases in the segregation band was affected by the inoculation. The size of α-Al15(Fe, Mn)3Si2 phase in Al–Ti–B inoculated alloys was refined, and the number significantly increased, resulting in a decrease in tensile strength of 12.82 MPa. In the Al–Nb–B inoculated alloys, the size and number of α-Al15(Fe, Mn)3Si2 phase decreased, and the δ-Al4FeSi2 phase increased, which effectively improved the fracture toughness and ductility. In addition, with the increase in grain refinement (from unrefined to Al–Ti–B to Al–Nb–B inoculated alloy), the fracture behavior changed from trans-granular fracture to intergranular fracture, improving the fracture toughness.

Experimental constitutive relationships for high-temperature deformation of as-cast Al–Si binary alloys

ABSTRACT As-cast binary Al–Si alloys containing ∼2 to 30 wt.% Si were deformed by differential strain rate and differential temperature test techniques at 600–840 K and strain rates 10−4–10−2 s−1 to find the parameters of the constitutive relationships for high-temperature deformation. The maximum strain rate sensitivity index (m) of flow stress was found to be 0.28 in the eutectic Al-12Si alloy. The Arrhenius plot for activation energy for deformation (Q) exhibits bilinear behaviour, with Q being greater at higher test temperatures than at lower temperatures. The magnitude of Q varies as a function of Si content: 95.7 ± 9.8 kJ/mol for Al-2Si to 311.4 ± 98.1 kJ/mol for Al-12Si alloy. Also, the constant initial strain rate tests performed at selected strain rates and temperatures revealed flow hardening at small strains followed by flow softening. Deformation of Al–Si alloys is suggested to be controlled by the dislocation climb mechanism through the participation of both the grain interior and grain boundaries by consideration of effective stress instead of applied stress.

Effect of heat treatments on inhomogeneous deformation of the melt-pool structure of Al–Si alloy manufactured via laser powder bed fusion

Laser powder bed fusion (L-PBF) is an additive manufacturing technology widely applied to the manufacture of metallic parts. The L-PBF processed aluminum-silicon (Al–Si) cast-type alloy components exhibit an anisotropic tensile ductility. In this study, we investigated the influence of heat treatments on the microstructural features of an Al–12%Si binary alloy fabricated via L-PBF and the associated inhomogeneous deformation of its melt-pool structure, which contributes to the resulting anisotropic tensile ductility. The mechanical inhomogeneity of the melt-pool structure and the change induced by annealing at various temperatures (300 and 530 °C) were characterized using microscale digital-image correlation analyses of scanning electron microscopy images obtained in situ during tensile deformation and nanoindentation hardness mapping. In the specimen fabricated via L-PBF, the high strain was concentrated at the locally coarsened microstructure (the soft region) along the boundaries of the melt pools rather than at the refined solidification microstructure (the hard region) within the melt pools. The localized strain varied depending on the geometrical relation between the orientation of the melt-pool boundary and the tensile direction, thus contributing to the anisotropic tensile ductility. This tendency appeared less pronounced in the specimen annealed at 300 °C, which exhibited a slightly homogenized melt-pool structure. The reduced strain localization is associated with a reduced difference in local strength between the melt-pool boundary (soft region) and the melt-pool interior (hard region). The slight homogenization of the melt-pool structure emphasized the effect of grain morphologies in the α-Al matrix on the inhomogeneous deformation within melt pools. In the specimen annealed at 530 °C, which exhibited a homogenized α-Al/Si two-phase microstructure, the uniformly distributed Si phase would be responsible for the homogenous deformation, resulting in an isotropic tensile ductility. This study advances our understanding of the correlation between the melt-pool structure and the deformation behavior of Al–Si alloys processed using L-PBF, which provides new insights for controlling the ductility by post-processing.

Hall-Petch relationship in multiscale cellular structures of Al-Si alloy fabricated by laser powder bed fusion

Material-structure-property integration is a promising development trend of additive manufacturing (AM). Nowadays, the material-property (M-P) relationships and structure-property (S-P) relationships of AM components have been extensively investigated. However, it is still unclear whether there is a relationship between M-P and S-P. Microscale cellular structure (ICS) is a typical microstructure in laser powder bed fusion (LPBF) processed metals, while macroscale cellular structure (ACS) is often fabricated by LPBF and are widely applied in industrial fields. Here, the solid material of AlSi10Mg alloy and ACS inspired by the ICS of AlSi10Mg were fabricated by LPBF. The scanning electron microscope (SEM) and electron backscatter diffraction (EBSD) analysis revealed that reducing the laser power from 400 W to 300 W would increase the mean diameter of ICS from 0.4 μm to 0.9 μm, but the grain size remained almost unchanged. The micro-CT results indicated that the LPBF fabricated ACS had high relative density and dimensional accuracy. Through Hall-Petch equation, the relationship between M-P of AlSi10Mg alloy and S-P of cellular structure was established. The present investigations provide a way to predict microstructure properties from the macrostructure properties, and vice versa, which will facilitate the material-structure-property integration of AM technology.

Dendritic Si growth morphologies in highly undercooled Al–Si alloys

The morphology of primarily crystallizing Si in hypereutectic Al-(20, 40, 55) wt%Si alloys during conventional casting (nucleation undercooling ΔT<1 K) and solidification at high undercoolings (ΔT up to 335 K) has been investigated. As expected, at higher undercoolings a higher nucleation frequency and fast growth of primary Si is observed, leading to the formation of multiple microstructural zones. Instead of the well-known plate-like Si in the as-cast microstructure, various morphologies of primary Si such as faceted and non-faceted blocky morphologies as well as dendrites with aligned side branches showing constant spacing features are observed after solidification at high undercoolings. The special Si dendrites only grow in a limited range of melt concentrations and undercoolings. The transition from faceted to non-faceted growth appears to occur in several steps, as Si dendrites with similar features of the secondary arms as in non-faceted metal alloys are also observed.

Influence of Mg and Cu on precipitation behaviors and mechanical properties of Al–Si alloys

Al–8Si-0.5 Mg, Al–8Si–2Cu, and Al–8Si–2Cu-0.5 Mg alloys have been designed in this study, aiming to reveal the influence of Mg and/or Cu additions on microstructures and mechanical properties of Al–Si alloys. Transmission electron microscopy (TEM), differential scanning calorimetry (DSC) and the Kampman-Wagner Numerical (KWN) model have been used to investigate age-hardening behaviors as well as their relation to mechanical properties. Microstructure analysis suggest that β'', θ′ and QP precipitates have formed in peak-aged Al–8Si-0.5 Mg, Al–8Si–2Cu and Al–8Si–2Cu-0.5 Mg alloys, respectively. Notably, the Al–8Si–2Cu-0.5 Mg alloy exhibits faster precipitation kinetics, larger age-hardening response and remarkable thermal stability compared to the other two alloys. Theoretical calculations indicate that the nucleation of QP precipitates is easier than β'' and θ′ precipitates, but the slower diffusivity of Cu limits the growth rate of QP precipitates during the growth stage. Furthermore, the contribution of β'', θ′ and QP precipitates to yield strength of peak-aged Al–Si alloys has been quantified, which shows a significant variation. β'' precipitates in the Al–8Si-0.5 Mg alloy exhibit the highest strengthening effect (∼186.4 MPa), followed by QP precipitates in Al–8Si–2Cu-0.5 Mg (∼160.2 MPa) and θ′ precipitates in the Al–8Si–2Cu alloy (∼13.4 MPa). This work provides valuable insights into the influence of Mg and/or Cu additions on the aging response and mechanical properties of Al–Si alloys, offering a reference for further enhancing the performance of Al–Si alloys.

Design and Optimization of Casting System for Integrated Longitudinal Beam and Tower Package Based on Al-Si Alloy

Design and Optimization of Casting System for Integrated Longitudinal Beam and Tower Package Based on Al-Si Alloy

Effect of Strontium Modification on Microstructure and Mechanical Property Al12SiCuMgNi Alloy in Squeeze Casting

Abstract The Al-Si series alloys, which have excellent fluidity and castability, are the most common aluminum material in the casting industry. However, the coarse eutectic Si phase with laminar morphology leads to the stress concentration of material and has a detrimental effect on the mechanical properties of aluminum alloy components. In this study, the Strontium (Sr) modifier was added to Al12SiCuMgNi alloy and the effect of Sr on microstructure and performance of Al12SiCuMgNi in squeeze casting was investigated. The experimental results show that the eutectic Si phase was well modified to fibrous morphology. Although the yield strength (YS) was leveled, the ultimate tensile strength (UTS) and elongation (EL) of the alloy were obviously enhanced after Sr addition. When the 0.012wt.% Sr was added to Al12SiCuMgNi alloy. The YS, UTS, and EL of alloys were up to 311 MPa, 401 MPa, and 3.4%, respectively. Moreover, the microstructure and performance of Al12SiCuMgNi alloy in the hot forging process were also compared to Al12SiCuMgNi alloy with and without Sr addition in squeeze casting. It is concluded that the Al12SiCuMgNi alloy in hot forging shows higher ductility (4.7%) and lower strength than Al12SiCuMgNi alloy in squeeze casting.

Wire-feeding friction stir welding for large-gap width tolerances

A novel method, named wire-feeding friction stir welding, was proposed for welding large-gap-width joints. Continuous wire feeding and welding systems were designed. AA6082-T6 aluminium alloy plates with a gap width of 2 mm were welded using Al–Si alloy wires as the filler materials. Sound joints were obtained even if the gap width reached over 2/3 thickness of the base materials. Fine microstructures were obtained via dynamic recrystallisation induced by severe plastic deformation. The ultimate tensile strength of the joints reached 253.4 ± 1.3 MPa. The adaptability to working conditions of friction stir welding was improved for long welds of high-speed railway, ship and aircraft.

Effect of the Melt Cooling Rate on the Structural-Phase State of the Al–Si Alloy Doped with Metals

Effect of the Melt Cooling Rate on the Structural-Phase State of the Al–Si Alloy Doped with Metals

Regulation to Ag–Al spikes through silver aluminum paste with Al–Si alloy

It is known that metallization of Ag–Al pastes to boron doped emitter of N-type solar cells will reduce contact resistance, because Al will promote forming Ag–Al spikes, providing conductive channels. However, deeper Ag–Al spikes will exacerbate metal recombination and deteriorate cell performance, thus requiring regulation. It has been reported that adding Si to Ag–Al pastes could effectively limit the formation of Ag–Al spikes, but it will increase grid line resistance and reduce conductivity. Based on this, we prepared new Ag–Al pastes using Al–Si alloys, which effectively regulated Ag–Al spikes and ensured electrical properties. In addition, we comprehensively compared the contact properties of conventional Ag–Al pastes, Ag–Al pastes with added Si, and Al–Si alloy pastes. The results indicated that conventional Ag–Al pastes have lower contact potential barriers and better contact performance, but Ag–Al spikes are difficult to control. Adding Si to Ag–Al pastes effectively limited the formation of spikes, but it will significantly increase potential barriers and deteriorate electrical performance. By contrast, using Al–Si alloys can not only achieve comprehensive regulation of the size and composition of Ag–Al spikes, but also ensure good electrical performance. This study developed Al–Si alloy pastes with great potential for application, which were of great significance for regulation of Ag–Al spikes and the development of advanced Ag–Al pastes.

Analysis of Fe-, Cu-, Mg- and Sr-Based Phases in Al–Si Alloys: Role of P Addition

Analysis of Fe-, Cu-, Mg- and Sr-Based Phases in Al–Si Alloys: Role of P Addition

Scalable synthesis of porous silicon electrodes for lithium-ion batteries via acid etching of atomized Al–Si alloy powders

Scalable synthesis of porous silicon electrodes for lithium-ion batteries via acid etching of atomized Al–Si alloy powders

Effect of thermal treatments on the surface electrical conductivity of AlSi7Mg produced by laser powder bed fusion

In the last years, the production of hypoeutectic Al-Si waveguide components by metal additive manufacturing has gained increasing attention in the telecommunications industry. The performances of waveguide components are influenced primarily by dimensional tolerances, surface electrical conductivity, surface roughness, and dimensional accuracy. Among these properties, electrical conductivity is known to be strongly influenced by the structural and microstructural characteristics of the alloys.In this work, microstructural and structural properties of an hypoeutectic Al-Si alloy, namely the AlSi7Mg alloy, were studied using FESEM, DSC, and XRD to understand how different thermal treatments (stress relieving, T5, and T6) affect the surface electrical conductivity. In the end, the most suitable thermal treatment to be applied to this alloy to maximize its electrical conductivity and, therefore, its appeal for microwave waveguide components is identified.

Optimizing Tribological and Mechanical Properties of Hypereutectic Al–Si Alloys Through Advanced Grain Engineering and Graphene Reinforcement

Optimizing Tribological and Mechanical Properties of Hypereutectic Al–Si Alloys Through Advanced Grain Engineering and Graphene Reinforcement