Hypereutectic Al-Si Research Articles

Influence of Cooling Rate on Primary Silicon Size in Hypereutectic Al–Si Alloy Fabricated by Laser Powder Bed Fusion

Herein, the effects of cooling rate on primary silicon (Si) phases in laser powder bed fusion (PBF‐LB/M) processed hypereutectic Al–Si alloy are investigated. These alloys are particularly in demand for automotive and electronic applications, thanks to their excellent wear and thermal properties. Nevertheless, when processed by conventional methods like casting with comparatively lower cooling rates, the coarse primary Si phases are responsible for increasing brittleness and inducing crack propagation. The refinement of the primary silicon phases is aimed to be achieved through the PBF‐LB/M process, which offers a high cooling rate. The primary Si phases are observed under three different thermal substrate plate conditions—untempered, with cooling and heating, and additionally with varying volume energy density. Furthermore, the impact of primary Si size on the hardness of the fabricated samples is evaluated. The findings show that a faster cooling rate has a notable effect on refining the primary Si size. Then, hardness is directly affected by the primary Si size, with larger Si resulting in decreased hardness.

Refinement of Primary Si Phase in Hypereutectic Al–Si Alloy by Electrically Assisted Solidification with P Addition

Refinement of Primary Si Phase in Hypereutectic Al–Si Alloy by Electrically Assisted Solidification with P Addition

Effect of Sb and Al–3P Complex Modification on Solidified Microstructure and Mechanical Property of Hypereutectic Al–18Si Alloys

Effect of Sb and Al–3P Complex Modification on Solidified Microstructure and Mechanical Property of Hypereutectic Al–18Si Alloys

Effect of friction stir processing on grain refinement and superplastic properties of binary Al-8 wt.% Si to Al-30 wt.% Si alloys

ABSTRACT As-cast binary Al–Si alloys containing ∼8, 12, 20, and 30 wt.% Si, representing the hypoeutectic, eutectic (12 wt.% Si), and hypereutectic compositions, were subjected to severe plastic deformation by friction stir processing (FSP) for grain refinement to 2.3–2.7 μm by dynamic recrystallization. Tensile tests conducted by differential strain rate test technique over the strain rates of 10−4 – 10−2 s−1 and test temperatures in the range of ∼840–530 K led to strain rate sensitivity index (m) varying from ∼0.04 to 0.40 depending on temperature, strain rate, and alloy composition. The constant initial strain rate tests conducted at 10−4 s−1 and 840 K exhibited a maximum elongation of 250% in the hypereutectic Al–20Si alloy, but the same increased linearly with m irrespective of alloy composition. Generally, with increasing Si content, the activation energy for deformation increased from 104.7 ± 14.4 kJ/mol for eutectic Al–12Si to 310.4 ± 32.3 kJ/mol for hypereutectic Al–30Si, which increased further to 572 ± 148 kJ/mol over the higher temperature range of 840–800 K. Analysis of observed deformation and microstructure behaviour supports the occurrence of superplasticity, whereby the accommodation of grain boundary sliding by grain boundary migration led to enhanced grain growth or else the local high-stress concentration at the particle-matrix interface led to cavity formation. There was no evidence of dynamic recrystallization during high-temperature tensile deformation but the flow softening observed is ascribed to the occurrence of concurrent cavitation.

Effect of multidirectional forging on grain structure and mechanical properties of hypereutectic Al–20%Si alloys with added refiners and modifiers

ABSTRACT The present work is focused on the multidirectional forging (MDF) of Al–20 wt-% Si alloys with the addition of refiners and modifiers. The MDF process was performed at 200°C with a cumulative strain of 0.63. Microstructural characterization and mechanical performance were evaluated on the Al–20Si, Al–20Si–4.5Cu, Al–20Si–4.5Cu–1(Al–Ti–B), Al–20Si–4.5Cu–1(Al–Ti–B)–10(Al–Sr). The microstructure analysis revealed significant changes in the eutectic and primary phase refinement. The micro-Vickers hardness confirmed that the MDF process resulted in increased hardness (125 ± 1.9 VHN) compared to the homogenized samples (96 ± 2.7 VHN). Tensile test results showed that with the accumulation of strain, ultimate tensile strength increased to 435 MPa from 302 MPa with reduction in the percentage of elongation from 7.8 to 5.6. The grains were more uniformly distributed with addition of modifiers, and refiners further reduced the nucleation number of eutectic grains. The wear study demonstrated that the wear resistance is more in the Al–Si-Cu-Sr sample due to the increased level of hardness. The combination of multidirectional forging techniques with judicious incorporation of refiners and modifiers engenders a synergistic enhancement of microstructural integrity, hardness profiles, and wear-resistant properties in hypereutectic Al-20Si alloys.

Microstructural refinement in a high elastic modulus Al-18Si-8Ni casting alloy

A new Al-Si-based casting alloy with high elastic modulus in the range of 90‐100 GPa and low density, less than 3 g/cm3, was developed by alloy design and microstructural refinement approaches. The addition of 8 wt.% Ni to a hypereutectic Al-18Si alloy introduces large volume fractions (∼40 vol.%) of hard primary Si and primary Al3Ni phases. Coarse primary Si and primary Al3Ni formed in the early stage of solidification, however, can interfere with the melt flow, reducing the castability, and also were deleterious to elongation. By the assessments of the crystallographic misfit between a nucleant substrate and a nucleated solid, we discovered key inoculants, AlP and TiB2, which can successfully refine such coarse and brittle primary phases, Si and Al3Ni, respectively. More importantly, along with the improved elastic modulus, the combined addition of AlP and TiB2 results in a significant increase in the elongation up to 1% with an advantageous yield strength of over 230 MPa. The important role of an inoculant, particularly TiB2 in nucleating the Al3Ni phase is also discussed based on the theoretical lattice misfit calculations and experimental characterization, further confirming their orientation relationship between the Al3Ni and the TiB2 as (110)[11¯0]Al3Ni∥ (0001)[12¯10]TiB2.

Effect of Glass Tube Suction Casting on Solidification Process and Si Refinement of Hypereutectic Al–Si Alloy

Effect of Glass Tube Suction Casting on Solidification Process and Si Refinement of Hypereutectic Al–Si Alloy

Refinement of Primary Si Phase in Hypereutectic Al–Si Alloy by Electrically Assisted Solidification with P Addition

The efficient processing of hypereutectic Al–Si alloys depends on controlling the microstructure of the primary Si phase during solidification. This study investigates the effects of electric current and phosphorus (P) addition on the refinement of primary Si, with the results confirming that applying electric current during solidification refines the primary Si phase; introducing P further enhances this refinement. Notably, when 10 ppm of P is added (below the identified critical amount of 20 ppm), an improved refinement effect is observed compared with the application of either electric current or P alone. Applying an electric current generates a circulating flow within the melt, resulting in an increased cooling rate, which leads to improved nucleation behavior for the primary Si phase. In addition, the circulating flow generated within the melt influences the dispersion of aluminum phosphide during nucleation. Adding P at concentrations above 40 ppm does not yield further benefits, suggesting a saturation point for its efficacy. This study demonstrates that the concurrent electric current application and minimal P addition can significantly enhance the refinement of primary Si phases, offering a potent approach for optimizing the microstructural properties of hypereutectic Al–Si alloys.

Optimizing the microstructure and enhancing the mechanical prsoperties of hypereutectic Al–Si alloys by Mg addition

The impact of Mg on the solidification structure of hypereutectic Al–Si alloys with different Si contents (15 wt% and 18 wt%) was investigated. 3%Mg was added to Al–15Si alloy to modify the phases in the solidification structure for the improvement of mechanical properties, and T6 heat treatment was used to optimize the microstructure and precipitate strengthening phase. The solidification structure was observed by OM and TEM respectively, and the precipitation behavior of each phase was detected through DSC. The results show that the addition of Mg decreased the undercooling of the alloy melt, thus suppressing the precipitation of primary Si phase. Nanoscale β” precipitates were precipitated in the matrix after T6 heat treatment. This resulted in an increase of 54% and 165% in the UTS and EL of the alloy, reaching 252 MP and 15.1%, respectively. Primary Si crystals were present in two forms in Al–18Si–8Mg alloy: spinel twin and non-twin, while Mg2Si always maintained the faceted crystals during the growing process, where only (100) and (111) crystal planes were observed. XRD, SEM and EBSD have been used to prove that Mg2Si crystals with different morphologies could become the heterogeneous nuclei of two types of primary Si crystals. The process of nucleation and growth of primary Si with Mg2Si as the heterogeneous nuclei was experimentally analyzed and theoretically predicted.

Enhancement of Tensile Strength of Coconut Shell Ash Reinforced Al-Si Alloys: A Novel Approach to Optimise Composition and Process Parameters Simultaneously

The research presents a novel approach to develop high-strength functionally graded composite materials (FGCMs) by using recycled coconut shell ash (CSA) particles as reinforcement for a hypereutectic Al-Si alloy matrix. Using a centrifugal casting technique, test specimens are prepared for the study under ASTM standards. The optimal combination of materials to maximise the materials’ overall tensile strength is obtained through the mixture methodology approach. The results show that CSA particles in the matrix material increase the tensile strength of the produced material. Process parameters, melting temperature and rotating speed were found to play a pivotal role in determining the tensile strength. A better tensile strength of the material is obtained when Al-Si = 90.5 wt%, CSA = 9.5 wt%, rotating speed = 800 RPM, and melting temperature = 800 °C; the proposed regression model developed has substantial predictability for tensile strength. This work presents a methodology for enhancing the tensile strength of FGCMs by optimising both the material composition and processing parameters. The achieved tensile strength of 197.4 MPa, at 800 RPM and 800 °C, for a concentration of 7.5 wt% CSA particles, makes these FGCMs suitable for use in multiple engineering sectors.

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.

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

Aluminium-Silicon Lightweight Thermal Management Alloys with Controlled Thermal Expansion

With the ever-growing emphasis on global decarbonization and rapid increases in the power densities of electronics equipment in recent years, new methods and lightweight materials have been developed to manage heat load as well as interfacial stresses associated with coefficient of thermal expansion (CTE) mismatches between components. The Al–Si system provides an attractive combination of CTE performance and high thermal conductivity whilst being a very lightweight option. Such materials are of interest to industries where thermal management is a key design criterion, such as the aerospace, automotive, consumer electronics, defense, EV, and space sectors. This paper will describe the development and manufacture of a family of high-performance hypereutectic Al–Si alloys (AyontEX™) by a powder metallurgy method. These alloys are of particular interest for structural heat sink applications that require high reliability under thermal cycling (CTE of 17 μm/(m·°C)), as well as reflective optics and instrument assemblies that require good thermal and mechanical stability (CTE of 13 μm/(m·°C)). Critical performance relationships are presented, coupled with the microstructural, physical, and mechanical properties of these Al–Si alloys.

Microstructure and mechanical properties of a hypereutectic Al–Si–Cu alloy manufactured by laser powder bed fusion

A novel Al–Si–Cu alloy was designed for additive manufacturing of automotive components, such as pistons and supercharger rotors, requiring a combination of elevated temperature properties and high cycle fatigue strength. The alloy was designed with an Al–Si hypereutectic chemistry to exploit the formation of primary Si nucleants to enable an equiaxed as-printed microstructure during laser powder bed fusion (LPBF). The alloy design space was assessed using a combined integrated computational materials engineering (ICME) approach with melt-spinning experiments to select a chemistry exhibiting primary Si nucleants acting as heterogeneous grain nucleation sites. Scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) of the LPBF as-printed samples revealed primary Si particles with a fully equiaxed grain structure and no apparent texturing as evaluated using electron backscatter diffraction (EBSD). High-resolution scanning transmission electron microscopy (STEM) revealed sub-micron Si particles and Al2Cu θ-phase precipitates which result in enhanced room and elevated temperature mechanical strength (room temperature: UTS: 449 ± 10 MPa, YS: 336 ± 12 MPa) as compared to commercial Al10SiMg (UTS: 417 ± 3 MPa, YS: 236 ± 6 MPa).

Large supercooling of Al[sbnd]Si alloy in microcapsule composed of Al2O3 shell

Al–Si-based microencapsulated phase change materials (MEPCMs) with a eutectic temperature of 577 °C are promising thermal energy storage (TES) materials owing to their large latent heat. Various preparation methods for Al–Si-based MEPCMs with Al2O3 shells have been reported; interestingly, Al–Si-based MEPCMs have large supercooling that does not depend on the preparation method. Supercooling is an important property of MEPCMs in the engineering aspects of designing a TES system. However, limited studies have reported the mechanism of supercooling in MEPCM. Moreover, the large supercooling of AlSi alloys in microcapsules compared with bulk materials is an interesting phenomenon in the field of physical chemistry. This study investigates the supercooling phenomenon in eutectic, hypoeutectic, and hypereutectic AlSi alloy MEPCMs, that is, AlSi alloys in a microcapsule comprising an Al2O3 shell. For the MEPCM with a hypoeutectic composition, supercooling is not observed because the primary Al acts as a nucleation site. For MEPCMs of eutectic and hypereutectic compositions, supercooling is observed at 25–37 °C. When the MEPCMs are heated to 1000 °C and then cooled, the supercooling degree increases significantly. In MEPCMs with a hypoeutectic composition, the precipitation of primary Al crystals does not occur under these conditions. Such findings contribute to the optimization of the design and operation of TES systems.

Study on the Forming Process and Properties of AlSi60 Alloy by Selective Laser Melting

Hypereutectic Al-Si alloys, which have a silicon content ranging from 12% to 70%, are a new generation of casing materials for chip packaging. They have broad applications in aerospace, weaponry, and civilian communications. Selective Laser Melting (SLM) offers significant advantages in achieving near-net shaping of complex casings. This paper presents a study on the formation defects, microstructure, and room temperature tensile properties of AlSi60 alloy prepared by SLM. The results indicate that the primary forming defects in the SLM AlSi60 alloy are balling, lack of fusion, and porosity. These defects are mainly influenced by the volumetric energy density. Samples of good quality can be produced within the range of 150 J/mm3 to 250 J/mm3. However, the same volumetric energy density can result in differences in sample quality due to various combinations of process parameters. Therefore, it has been determined that a well-formed AlSi60 alloy can be obtained within a laser power range of 300 W–350 W, scanning speed of 400 mm/s–800 mm/s, and hatch spacing of 0.09 mm–0.13 mm, with a density close to 98%. The microstructure of the SLM AlSi60 alloy consists of primary Si phases with irregular shapes and sharp edges measuring 5–10 μm, eutectic Si particles of 0.5 μm, and α-Al phases, with eutectic Si dispersed within the α-Al. The SLM AlSi60 alloy exhibits fine and evenly distributed primary Si phases with an average hardness of 203 HV. No significant anisotropy in hardness values was observed in the X and Y directions. The tensile strength of the alloy reached an average of 219 MPa, with an average elongation of 2.99%. During the tensile process, cracks initiated by the primary Si phases rapidly expanded, exhibiting minor ductile fracture characteristics in the Al phases. Due to the high volume fraction of Si phases, the tensile test was dominated by brittle fracture. The tensile curve only exhibited the elastic stage.

Tribological Behaviour of Hypereutectic Al-Si Composites: A Multi-Response Optimisation Approach with ANN and Taguchi Grey Method

An optimisation model for small datasets was applied to thixocasted/compocasted composites and hybrid composites with hypereutectic Al-18Si base alloys. Composites were produced with the addition of Al2O3 (36 µm/25 nm) or SiC (40 µm) particles. Based on the design of experiment, tribological tests were performed on the tribometer with block-on-disc contact geometry for normal loads of 100 and 200 N, a sliding speed of 0.5 m/s, and a sliding distance of 1000 m. For the prediction of the tribological behaviour of composites, artificial neural networks (ANNs) were used. Three inputs were considered for ANN training: type of reinforcement (base alloy, Al2O3 and SiC), amount of Al2O3 nano-reinforcement (0 and 0.5 wt.%), and load (100 and 200 N). Various ANNs were applied, and the best ANN for wear rate (WR), with an overall regression coefficient of 0.99484, was a network with architecture 3-15-1 and a logsig (logarithmic sigmoid) transfer function. For coefficient of friction (CoF), the best ANN was the one with architecture 3-6-1 and a tansig (hyperbolic tangent sigmoid) transfer function and had an overall regression coefficient of 0.93096. To investigate the potential of ANN for the prediction of two outputs simultaneously, an ANN was trained, and the best results were from network 3-5-2 with a logsig transfer function and overall regression coefficient of 0.99776, but the predicted values for CoF in this case did not show good correlation with experimental results. After the selection of the best ANNs, the Taguchi grey multi-response optimisation of WR and CoF was performed for the same combination of factors as the ANNs. For optimal WR and CoF, the combination of factors was as follows: composite with 3 wt.% Al2O3 micro-reinforcement, 0.5 wt.% Al2O3 nano-reinforcement, and a load of 100 N. The results show that developed ANN, the Taguchi method, and the Taguchi grey method can, with high reliability, be used for the optimisation of wear rate and coefficient of friction of hypereutectic Al-Si composites. Microstructural investigations of worn surfaces were performed, and the wear mechanism for all tested materials was light abrasion and adhesion. The findings from this research can contribute to the future development of hypereutectic Al-Si composites.

Interfacial characteristics of dual-phase Si/TiB2 and its crack initiation mechanism in hypereutectic Al-Si alloys

Al-17Si-4Cu and 6 wt% TiB2/Al-17Si-4Cu composites are generated using an in-situ reaction in this study. The impact of TiB2 ceramic particles on the morphology, size and distribution of primary Si in the composites and the properties of the composites are studied. Based on the results of transmission electron microscopy, the work of adhesion (Wad), interfacial energy and electronic structure of the TiB2/Si structure are calculated using first-principles calculations. Si-Ti triple bonds are formed at the Ti-terminated stacking model interface, while Si-B double bonds form at the B-termination interface model after structural energy optimization. In the TiB2/Si stacking interface models, the Ti termination model has the highest interfacial bonding strength, a Wad of 2.6 J/m2, the smallest interface distance (d0 = 1.874 Å) and the lowest interfacial energy (0.216 J/m2). The analysis of the interfacial bonding properties indicates the formation of Si-Ti covalent bonds and metal bonds at the Ti-terminated interface. Conversely, weak covalent bonds and ionic bonds are observed at the B-terminated interface model. These findings suggest that the Ti-terminated interface model exhibits significant interfacial stability. The experimental results are verified by first-principles calculations. Finally, in-situ scanning electron microscopy demonstrates that TiB2 can hinder the crack initiation and propagation path change of primary Si in the Al-17Si-4Cu alloy. The modulus and microhardness results show that the addition of TiB2 endows the dual phases of TiB2 and primary Si with a stronger ability to maintain the original morphology and structure, illustrating that they are significantly strengthened by the incorporation of TiB2 particles. This research offers valuable theoretical guidance into the enhancement of ceramic-reinforced aluminum matrix composites.

Effect of heat treatment on microstructural characteristics and mechanical properties of hypereutectic B390 aluminium alloys modified by phosphorus and bismuth

This study investigated the effects of solution treatment and aging processes on microstructural characteristics and mechanical properties of hypereutectic B390 Al-Si Alloy modified by phosphorus (P) and bismuth (Bi). The morphology evolution of primary Si, eutectic Si, intermetallic compounds, and secondary dendrite arm spacing (SDAS) of both initial and modified alloys were investigated in as-cast and heat-treated conditions. It was found that the combination of 0.1 wt%P and 0.5 wt%Bi in B390 alloy resulted in a remarkable modification and refinement of primary Si, eutectic Si, and SDAS compared to initial specimens in the as-cast condition. After heat treating, the fine lamellar eutectic Si and intermetallic compounds underwent a higher degree of fragmentation and coarsening, appearing as small round particles, leading to a more pronounced formation of a supersaturated solid solution. Additionally, the peak aging time of the B390-P-Bi alloy was only 7 h, 2 h less than the initial specimen. After T6 treatment and addition of both 0.1 wt%P and 0.5 wt%Bi, the B390-P-Bi alloy exhibited a smaller rounded Mg3Bi2 phase at peak aging with a 62.07% size reduction compared to the B390-Bi alloy. The results show that adding P with Bi enhanced hardness, ultimate tensile strength (UTS) and elongation because of refinement of the SDAS, primary Si and eutectic Si. These refinements played a crucial role in increasing tensile strength by more effective strengthening through precipitation and grain size reduction. The B390-P-Bi alloy is a promising choice for applications requiring a balance between strength and ductility.

Comparative Study on the tribological performance and wear behaviour of hypereutectic Al–Si cylinder liner surfaces textured using micro-drilling and mechanical indentation-based approaches

Thermally-induced microstructural changes and the requirement of expensive equipment are the deterring aspects of using laser-based texturing for tribological applications. This study presents two texturing methods based on mechanical indentation and micro drilling on hypereutectic Al–Si cylinder liner surfaces. Etched hypereutectic Al–Si specimens were textured at three distinct texture spacings (1 mm, 1.5 mm, and 2 mm) and tested against a piston ring using a linear reciprocating tribometer at 30 °C, 80 °C, and 160 °C under boundary lubrication regime to study their tribological behaviour. Forty-eight experimental runs were performed based on the design of experiments method to investigate the effect of the texture generation method, texture spacing, and temperature on the friction and wear behaviour of the textured cylinder liner against a chrome-coated piston ring, and the results are compared with bare, unetched and untextured Al–Si specimens. Wear rates and wear mechanisms of Al–Si cylinder liners subjected to both texturing approaches under sliding conditions were investigated. Mechanical indentation with texture spacing of 1 mm exhibited optimum tribological performance with low friction coefficient and wear values in comparison to micro-drilled and non-textured liner surfaces. Texture spacing of 2 mm is observed to show a negative effect on tribological performance for every experimental run.