As a promising anti Si-poisoning grain refiner, Al-V-B master alloys have gained increasing attention in the past several years. However, the effect of V:B ratio on the grain refinement effect, as well as the refining mechanism has not been clearly investigated. This work investigates the impact of V:B ratio on microstructures of Al-V-B master alloys and grain refinement efficacy for α-Al grains in AlSi alloys. In addition, the effect of rolling treatment on the agglomeration and sedimentation of Al-V-B master alloys has been investigated. It demonstrates that the V:B ratio significantly affects primary secondary phases within Al-V-B master alloys, with an optimal ratio of 2.33 (Al-4.2 V-1.8B) leading to the finest average α-Al grain size of ~98 μm in the Al8Si alloy. Moreover, rolling treatment further enhances the grain refinement efficacy of Al-4.2 V-1.8B master alloy by dispersing VB2 agglomerates/particles and reducing agglomeration and sedimentation during smelting. Accordingly, the rolled Al-4.2 V-1.8B master alloy reduces the average α-Al grain size to ~75 μm at only 50 % amount of the as-cast Al-4.2 V-1.8B master alloy, improving the grain refinement efficacy by 25 % (75 μm v.s. 98 μm). At the same time, the rolled Al-4.2 V-1.8B master alloy exhibits exceptional anti-fading ability, maintaining a stable grain refinement efficacy for up to 120 min. Cs-corrected transmission electron microscopy (TEM) reveals that VB2 particles act as primary nucleation sites for α-Al grains, with a specific crystallographic orientation relationship: [1 1 2¯ 0] (0001) VB2 || [1¯ 1 0] (111) α-Al. This study provides valuable insights into the design of Al-V-B master alloys with superior grain refinement efficacy and anti-fading ability for AlSi alloys.
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