β-Al5FeSi Phase Research Articles

The Influence of Iron Content on the Porosity of AlSi9 Alloy Intended for Alfining Piston Ring Inserts.

Due to its tendency to increase the power of engines, improving their reliability and operational efficiency, the compression ring in combustion engine pistons is embedded in a cast iron insert, which is subjected to the process of "alfining". This involves covering the insert with an Al-Si alloy, which increases the iron content. Research has shown that the β-Al5FeSi phases crystallizing in the area of the insert-piston connection are the main cause of an unstable connection between the silumin casting of the piston and the ring insert. Their unfavourable lamellar morphology and large dimensions are the main causes of weakening in the connection between the insert and the piston, resulting in an unacceptable number of defective products. It has also been found that up to approx. 0.59 wt.% Fe, the pore volume fraction is very small (up to 3%), and there is no correlation. However, after exceeding this value, both the volume fraction of the β-Al5FeSi phase and the number of pores increase monotonically to values of approximately 18% and 14%, respectively, and the correlation between the examined features is statistically significant. These results were compared with known theories of the influence of iron on the porosity of Al-Si alloys, showing that the precipitates of the β-Al5FeSi phase are more important in the porosity fraction than the two-layer oxide films called "bifilms". This research was carried out and verified under industrial conditions in one of the largest piston foundries (Federal-Mogul Gorzyce sp. z o.o., F-MG) on a separate line intended for alfining ring inserts intended for combustion pistons.

SEM-DIC characterization of the damage mechanism of an AlSi10Fe0.7 casting alloy on the microstructure scale

Various brittle phases are present in commercial cast aluminum alloys, which strongly influence their mechanical behavior. Among these, silicon precipitates are nearly omnipresent, as Si is a common alloying element. In secondary alloys, usually Fe-containing phases cannot be avoided, and they tend to degrade the mechanical properties. The interaction between the silicon phase and the failure-critical intermetallic phase in the Al-Si-Fe phase system (β-Al5FeSi) is studied in this paper in high resolution. A model alloy AlSi10Fe0.7 was defined, which is composed of a large grain Al-matrix, Si-precipitates and the plate-like β-Al5FeSi phase. The goal of the study was to identify “hot spots” in the microstructure from which cracks may initiate under mechanical loading. The main tool was a deformation analysis via digital image correlation in the SEM (SEM-DIC). This allows the identification and tracking of developing strain localizations at different potential crack initiation sites with a high resolution as well as capturing an overview over the whole specimen. An adapted frame averaging script minimized measurement errors induced by drift. The SEM-DIC results show that the deformation field is governed by the elastic incompatibility of the microstructural constituents. Crack initiation occurs because of the detachment of the Si + β-Al5FeSi phase boundary. Cracks then cross the phase boundary and propagate along twin boundaries in the β-Al5FeSi phase. Final failure is caused by linking fractured brittle plate-like particles.

A Quantitative Phase Analysis by Neutron Diffraction of Conventional and Advanced Aluminum Alloys Thermally Conditioned for Elevated-Temperature Applications.

As the issue of climate change becomes more prevalent, engineers have focused on developing lightweight Al alloys capable of increasing the power density of powertrains. The characterization of these alloys has been focused on mechanical properties and less on the fundamental response of microstructures to achieve these properties. Therefore, this study assesses the quality of the microstructure of two high-temperature Al alloys (A356 + 3.5RE and Al-8Ce-10Mg), comparing them to T6 A356. These alloys underwent thermal conditioning at 250 and 300 °C for 200 h. Time-of-flight neutron diffraction experiments were performed before and after conditioning. The phase evolution was quantified using Rietveld refinement. It was found that the Si phase grows significantly (13-24%) in T6 A356, A356 + 3.5RE, and T6 A356 + 3.5RE alloys, which is typically correlated with a reduction in mechanical properties. Subjecting the A356 3.5RE alloy to a T6 heat treatment stabilizes the orthorhombic Al4Ce3Si6 and monoclinic β-Al5FeSi phases, making them resistant to thermal conditioning. These two phases are known for enhancing mechanical properties. Additionally, the T6 treatment reduced the vol.% of the cubic Al20CeTi2 and hexagonal ᴨ-Al9FeSi3Mg5 phases by 13% and 23%, respectively. These phases have detrimental mechanical properties. The Al-8Ce-10Mg alloy cubic β-Al3Mg2 phase showed significant growth (82-101%) in response to conditioning, while the orthorhombic Al11Ce3 phase remained stable. The growth of the beta phase is known to decrease the mechanical properties of this alloy. These efforts give valuable insight into how these alloys will perform and evolve in demanding high-temperature environments.

Modification and strengthening of recycled Al-Mg-Si-based alloy upon continuous rheological extrusion (CRE) forming

With global warming and resource scarcity, it is crucial to devise a simple, energy-efficient, and low-emission recycling method for aluminum alloys. In the recycled Al-Mg-Si-based alloy, the coarse α-Al dendrites, the long plate-like β-Al5FeSi phase and bulk Mg2Si phase significantly impair the microstructure and mechanical properties of the alloys. In this works, combined the continuous rheological extrusion (CRE) technology with the addition of CRE Al-5.0Ti-1.0B (wt%) refiner, the recycled Al-Mg-Si-based alloy wires at extrusion ratios (ER) of 3, 5 and 7 were prepared. The refinement of Mg2Si and β-Al5FeSi phases and the grain refinement caused by the continuous dynamic recrystallization (CDRX) behavior in the CRE process were discussed. The strengthening mechanism of recycled Al-Mg-Si-based alloy was revealed. The results showed that, CRE technology and CRE Al-5.0Ti-1.0B (wt%) refiner can effectively refine Mg2Si and β-Al5FeSi phases, and even to the nanometer level. At the same time, the increase of ER and the addition of CRE Al-5.0Ti-1.0B (wt%) can promote the transformation of low angle grain boundaries (LAGBs) to high angle grain boundaries (HAGBs), thereby promoting the occurrence of CDRX. In addition, the increase of dislocations and nanophases caused by the increase of ER and the addition of CRE Al-5.0Ti-1.0B can effectively refine CDRX grains. When 0.2 wt% CRE Al-5.0Ti-1.0B (wt%) refiner was added at ER of 7, the ultimate tensile strength (UTS), yield strength (YS) and elongation (EL) of recycled Al-Mg-Si-based alloy were 259.40 MPa, 140.80 MPa and 18.20%, respectively. Grain boundary strengthening and dislocation strengthening were the primary mechanisms in enhancing the YS of the recycled Al-Mg-Si-based alloy.

Investigation of the Microstructure and Dry-Sliding Wear Behavior of Co Containing Al-Si-Fe Scrap Alloy

This study investigates the influence of cobalt (Co) addition on the microstructural and wear properties of an aluminum (Al) scrap alloy containing high iron (Fe) impurity content (3%). Microstructural analysis using scanning electron microscopy and optical microscopy confirmed the presence of Co in Fe-rich intermetallics. Upon increasing the Co concentration, β-Al5FeSi phase was seen to be refined without significant morphological modifications. Furthermore, Co addition promoted the formation of a new quaternary phase Al32Si7Fe4Co phase, which was finely distributed throughout the microstructure and acts as a tribo-layer in the Al scrap alloy, offering enhanced wear resistance and improved stability against wear. Standard EN-31 steel disk with compositions chromium (Cr)-1.6%, manganese (Mn)-0.75%, silicon (Si)-0.35%, and carbon (C)-0.9% was used for the wear test. Microhardness and wear properties were evaluated for both the as-cast and heat-treated alloys, with the as-cast samples exhibiting superior wear resistance and a lower coefficient of friction compared to the T6 heat-treated samples. Addition of Co showed refinement in the β-Fe rich intermetallics over the morphological modifications. Similarly, Co addition enhanced the hardness and wear resistance in the as cast alloys. This work provides a detailed analysis contributing significant understandings into the wear mechanisms and potential applications of Co modified recycled Al in various industrial sectors.

Effect of Mg/Si ratio on synergistic improvement of formability and yield strength in Al-Mg-Si-Zn alloys

The design of Al-Mg-Si-Zn series alloys combines the advantages of 6xxx and 7xxx series alloys and breaks through the limitations of strength and formability matching of traditional alloys. In this study, we achieved an exceptional strength-formability combination in the Al-0.84Mg-0.79Si-3.38Zn (wt.%) alloy. Following a solution treatment at 550 °C for 3 min, the alloy exhibited an elongation of ∼36.8%, with a yield strength of ∼356 MPa after artificial aging at 175 °C for 8 h. The effects of different Mg/Si ratios (∼0.6, ∼1.2, and ∼2.5, at.%) on the strength-formability interplay in Al-Mg-Si-Zn alloys were investigated. The alloy with a low Mg/Si ratio (∼0.6) facilitated the precipitation of fine β'' phases characterized by a high number density (∼8.4 nm−3 × 10−5). A Mg/Si ratio of ∼1.2 proved advantageous for precipitating larger β'' phases with a higher volume fraction (∼0.69%), resulting in an elevated precipitation strengthening effect (∼290 MPa). However, with an increase in the Mg/Si ratio to ∼2.5, the reduced availability of Si atoms for forming Mg-Si clusters led to a decrease in the number density of precipitates. Additionally, the interaction among Fe, Mn, and Si elements resulted in the presence of blocky α-Al(FeMn)Si phases, as opposed to the needle-like β-AlFeSi phases, in the alloy with a Mg/Si ratio of ∼1.2. This effectively prevented the degradation of elongation. Our findings present a comprehensive strategy for the compositional design of high-performance aluminum alloys.

Microstructure, segregation and mechanical properties of A356 alloy components fabricated by rheo-HPDC combined with the swirled enthalpy equilibration device (SEED) process

The challenges commonly associated with conventional high pressure die casting (HPDC) have led to increased interest in semi-solid metal (SSM) forming processes. In the present study, semi-solid slurries of A356 alloy prepared by the Swirled Enthalpy Equilibration Device (SEED) process were used for manufacturing components with complex shape by using a high pressure die casting machine. The segregation phenomenon and the effect of heat treatment on the microstructure evolution and mechanical properties were investigated. The results showed that the alloy consists of primary spherical α-Al grains, secondary solidified α-Al grains, eutectic Si, iron-rich intermetallic phases and low porosities. The microstructural investigations revealed that the eutectic Si particles underwent fragmentation, spheroidization and coarsening with increasing solution temperature. Furthermore, the solution treatment results in the dissolution of the π-Al8FeMg3Si6 phase and the growth of the β-Al5FeSi phase. The hardening peaks at 170 °C could be obtained with ageing for 5 h. Due to both solution and precipitation strengthenings, the yield strength, ultimate tensile strength and hardness of A356 alloy after heat treatment increase significantly compared to those in the as-rheocast state: they reach 266 MPa, 343 MPa and 110 HV0.2, respectively. The analysis of fracture surfaces of rheo-HPDC samples in both the as-rheocast and the heat-treated states revealed a mixed mechanism of dimples and quasi-cleavage. The microstructure inside the part was found to be quasi-homogeneous while the segregation phenomenon in different zones of the part is affected by die geometry during the filling process. The results imply that the SEED-HPDC process has the potential to be industrialized by implementing appropriate heat treatments for producing complex components with good mechanical properties.

Enhancing the Strength and Toughness of A356.2-0.15Fe Aluminum Alloy by Trace Mn and Mg Co-Addition

In the present work, microalloying is put forward to improve the microstructure and tensile properties of A356.2-0.15Fe (wt.%) alloy by the co-addition of trace Mn and Mg. A suitable Mn/Fe mass ratio of 0.5 is obtained for alloys with 0.15Fe. The yield strength, ultimate tensile strength, and elongation of the A356.2-0.15Fe alloy with an Mn/Fe ratio of 0.5 and containing 0.42 wt.% Mg is 179 MPa, 286 MPa, and 9.1%, respectively, which is acceptable for automotive wheel hub applications. Optical microscopy (OM), scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD), and electron-probe microanalyzer (EPMA) methods are used to characterize the microstructure of the alloys. The results indicate that Mn addition promotes the transformation of the acicular β-Al5FeSi phase to the block-shaped α-Al(Fe, Mn)Si phase. The ratio of length/width of the Fe-rich phase in the alloy is reduced by 78.8% with an Mn/Fe ratio of 0.5 and containing 0.35 wt.% Mg, compared with that of the alloy without Mn addition and containing 0.35 wt.% Mg. The addition of Mg reduces the secondary dendrite arm spacing (SDAS) from 26.1 μm to 20.9 μm. The volume fraction of the precipitated Mg2Si phase in the alloy containing 0.42 wt.% Mg increases by 60% compared with that in the alloy containing 0.35 wt.% Mg. The morphology transformation of the Fe-rich phase, the reduction of SDAS, and the increase in volume fraction of precipitated Mg2Si phase comprehensively contribute to the improvement of A356.2-0.15Fe alloy. The microstructure evolution mechanism and the effect of microstructure on tensile properties are analyzed and discussed.

The effect of Fe content on crystal phase and mechanical properties of 6061 aluminium alloy

In order to eliminate the adverse effects of impurity element Fe in aluminium alloy, the effects of Fe content on the microstructures and mechanical properties of 6061 aluminium alloy were studied utilizing scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and tensile testing machine. The results show that Fe exists mainly in α-AlFeSi and β-AlFeSi phases. Elemental Fe promotes the generation of fishbone shaped α-AlFeSi phase, while the percentage of needle shaped β-AlFeSi phase gradually decreases. After homogenizing annealing, the Mg2Si phase has been redissolved, and a large amount of Si element exists in the aluminium matrix. With the increase of Fe and Si content, β→α phase transition has been completed, and the fishbone α-AlFeSi phase accumulates at the grain boundary. After the extrusion forming process, the morphology of the α-Al12(MnFe)3Si phase changes from fishbone to granular, and the bulk deposition of α-Al12(MnFe)3Si improves the strength of 6061 aluminium alloy.

Enhanced comprehensive performance via alloying and rheo-diecasting in a semi-solid Al–Si–Fe–Mg–Cu–Sr alloy

A semi-solid Al alloy with superior comprehensive performance was obtained via alloying design concept and rheo-diecasting (RDC). The semi-solid alloy slurry was obtained via the vibrating contraction sloping plate. As the contents of Cu and Mg elements increased, the secondary dendrite arm spacing (SDAS) decreased and solubility of Cu and Mg elements increased, which improved the mechanical property and decreased the thermal conductivity of as-cast alloys. The effect of microstructure evolution induced by pouring temperature on mechanical properties at room and elevated temperatures, thermal conductivity, and corrosion behavior of the RDC alloy was investigated. The results demonstrated that the low porosity and refined primary α1-Al grains, secondary α2-Al grains, β-Al5FeSi phases, eutectic Si phases played a significant role in enhancing mechanical properties of the alloy at room temperature. Meanwhile, some submicron β-Al5FeSi phases effectively hindered grain boundary sliding, resulting in the increased mechanical properties of the alloy at elevated temperatures. The improvement in thermal conductivity was related to the decreased electron scattering due to the reduced porosity and small-sized secondary phases. The decrease in the potential difference between the β-Al5FeSi phase and matrix helped improve the corrosion resistance of the alloy.

Effect of high pressure on solidification microstructure evolution of near-eutectic Al-11.5Si-0.5Fe-0.2 Mg alloy

The microstructures evolution of near-eutectic Al-11.5Si-0.5Fe-0.2 Mg alloy solidified under different pressures (1 GPa and 3 GPa) were investigated. The results show that the increase in solidification pressure leads to a transition from the typical eutectic structure to the hypoeutectic structure of the alloy by increasing the melting point, and a change in the morphology of the eutectic Si phase from a needle-like structure to a short sheet-like structure and contact with each other. The increase of solid solubility drives the disappearance of the π-Al8FeMg3Si6 phase at 1 GPa, the disappearance of the α-Al8Fe2Si phase, and the occurrence of the δ-Al4FeSi2 phase at 3 GPa. The α-Al8Fe2Si phase and β-Al5FeSi phases are separated from each other in the matrix, indicating that these two phases are formed by independent reactions. In contrast, the β-Al5FeSi and δ-Al4FeSi2 phases can remain stable during solidification at higher pressures.

Synergistic Effect of RE (La, Er, Y, Ce) and Al-5Ti-B on the Microstructure and Mechanical Properties of 6111Aluminum Alloy

For aluminum alloys, grain refinement is one of the effective methods for improving both strength and ductility. However, the refining effect of Al-Ti-B master alloy refiners deteriorates due to the agglomeration and sinking of the second phase particles. In this paper, the effects of rare earth type, rare earth content, and holding time on the microstructure and properties of Al-5Ti-B + RE/6111 were investigated by orthogonal experiment. It was shown that the addition of rare earth promoted the transformation of the β-Al5FeSi phase to anα-Al15(Mn,Fe)3Si2 phase, while the segregation of rare earth made it difficult for TiB2 to aggregate and inhibited the growth of TiAl3, resulting in more particles becoming effective nucleation substrates. The Al-5Ti-B + Ce master alloy developed based on orthogonal experiment improved the refinement recession problem well and improved the comprehensive mechanical properties of 6111 aluminum alloy. It was found that the addition of Al-5Ti-B + 0.1Ce, which had an ultimate tensile strength of 240.4 ± 2.2 MPa, successfully reduced the grain size by 73.8% and improved elongation by 37.8% compared to the base alloy. There search is of great significance for the preparation and application of high-performance rare earth 6111 aluminum alloy.

Modification of Iron-Rich Phase in Al-7Si-3Fe Alloy by Mechanical Vibration during Solidification

The plate-like iron-rich intermetallic phases in recycled aluminum alloys significantly deteriorate the mechanical properties. In this paper, the effects of mechanical vibration on the microstructure and properties of the Al-7Si-3Fe alloy were systematically investigated. Simultaneously, the modification mechanism of the iron-rich phase was also discussed. The results indicated that the mechanical vibration was effective in refining the α-Al phase and modifying the iron-rich phase during solidification. The forcing convection and a high heat transfer inside the melt to the mold interface caused by mechanical vibration inhibited the quasi-peritectic reaction: L + α-Al8Fe2Si → (Al) + β-Al5FeSi and eutectic reaction: L → (Al) + β-Al5FeSi + Si. Thus, the plate-like β-Al5FeSi phases in traditional gravity-casting were replaced by the polygonal bulk-like α-Al8Fe2Si. As a result, the ultimate tensile strength and elongation were increased to 220 MPa and 2.6%, respectively.

Characterization of Al Alloys Injected through Vacuum-Assisted HPDC and Influence of T6 Heat Treatment

AlSi12(Fe), AlSi10Mg(Fe), AlSi10MnMg, and AlMg4Fe2 die-casting alloys were produced by high-pressure die casting (HPDC) and vacuum-assisted high-pressure die casting (VADC) under a vacuum level of 200 mbar. The chemical composition, hardness, gas and shrinkage porosity, and mechanical properties were analyzed. The parts under study were subjected to a T6 heat treatment. The VADC led to a decrease in the percentage of defects in the as-cast state for all the alloys, due to a reduction in the amount of gas porosities. After heat treatment, the quantity of gas and shrinkage porosities increased. The efficiency and level of vacuum used were not sufficient to improve the mechanical properties in the as-cast state. The ductility of AlSi10Mg(Fe) and AlSi10MnMg alloys was improved after heat treatment; however, the YS and UTS of AlSi10Mg(Fe) did not increase. The primary aluminum alloys presented higher elongation values than the secondary aluminum alloys due to the reduced amount of the needle-like β-Al5FeSi phase.

Investigating the Al/Si mixed site occupancy in the β-AlFeSi phase.

This work investigates the mixed site occupancy of aluminium and silicon atoms in the β-AlFeSi phase. For this purpose, the six mixed Al/Si sites of the β-AlFeSi structure were considered independent and alternatively substituted by Al or Si, thus generating 64 ordered structures or end-members. The enthalpy of formation of each end-member was calculated by DFT. These calculations allowed us to derive the enthalpy of mixing of the solid solution at 0 K, over a wide range of chemical compositions, from the Al-Fe binary system to the Si-Fe binary system. In addition, the heat capacities of the solid solution were determined using a Debye model based on the calculation of the elastic constants and the equation of state of each end-member. These heat capacity values were used along with the enthalpy of formation we calculated to determine the Gibbs free energies of all the end-members of the β-AlFeSi structure. Finally, the configurational entropy of mixing from the Compound Energy Formalism (CEF) for the configurational entropy of mixing was subsequently used to calculate the occupation fractions of the Si sites on the Al sites of the β-AlFeSi structure, at 300 K and 938 K, the latter being the thermal decomposition temperature of this compound. These original site occupancy data were used to quantify the chemical ordering of the solid solution and to compare different sublattice (SL) models. We thus highlight that the SL model of the β-AlFeSi solution most commonly accepted in the literature generates considerable errors in its thermodynamic description, contrary to the model proposed in this paper, which is both simple and particularly accurate, consisting in merging the sites Al(1)-Al(6), the sites Al(2)-Al(3) as well as the sites Al(4)-Al(5).

Researches on the Macro- and Micro-Structures and Properties of the Vertical Bending Continuous Casted AA6063 Thin Slabs and Their As-Rolled Sheets

A 6063 aluminum alloy thin slab with a cross-section of 260 × 40 mm2 was prepared by a vertical bending continuous casting (VC) process. The effects of homogenization, hot rolling and subsequent heat treatments on the microstructure and properties of the as-cast slabs and as-rolled sheets were investigated by scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), field emission electron probe (EPMA), macro- and micro-structure observation and tensile tests. The results show that the as-cast structure of AA 6063 was dominated by fine and uniform equiaxed grains. After homogenization, all Mg2Si phases dissolved back, and the Fe-containing intermetallic phases changed from acicular β-Al5FeSi phase to spherical α-Al8Fe2Si phase. Homogenizing heat treatment before hot rolling can improve the mechanical properties of the alloy. However, in the case of direct rolling without homogenization, the alloy still has good mechanical properties; the strength and plasticity are comparable to that obtained through traditional direct chill (DC) casting, homogenizing and extruding processes, indicating that the VC process has the potential to realize continuous casting and rolling.

Characterization of Refining the Morphology of Al–Fe–Si in A380 Aluminum Alloy due to Ca Addition

Aluminum–silicon (Al–Si) alloys are the most commonly cast aluminum alloys. Fe is the most deleterious element for Al–Si die casting alloys, as its existence causes the precipitation of substantial intermetallics that result in the unsatisfactory mechanical performance of the alloy, such as its ductility. Hence, controlling the morphology and formation of the AlFeSi phase, particularly the β-AlFeSi phase, is vital for improving the ductility of Al–Si die casting alloys. Herein, Ca was added to the A380 alloy, and the morphological changes resulting from the influence of Ca on the AlFeSi phase were characterized. The outcomes revealed that according to different cooling rates, specific amounts of Ca addition (0.01–0.1 wt.%) were capable of refining α-AlFeSi and β-AlFeSi morphology and transforming the β-AlFeSi phase into α-AlFeSi. Moreover, Ca addition could also modify eutectic silicon. The transformation mechanism and refining role of Ca in AlFeSi and the different morphologies of Al2CaSi2 were analyzed.

High-ductility AA6061 alloys produced by combination of sub-rapid solidification and Cr-alloying

Fe-containing phases had a critical influence on the mechanical properties especially the ductility of Al–Mg–Si alloys. In the present study, the Fe-containing phases in Al-1.2Mg-0.7Si-0.1Fe (wt.%, AA6061) alloys had been regulated by the combination of sub-rapid solidification (SRS) and alloying with 0.12 wt.% Cr. Consequently, the coarse needle/platelet β-Al5FeSi phases (average length: ∼27 μm) were regulated as polyhedral α-AlCrFeSi phases with smaller size (∼2 μm) and uniform distribution. Based on the thermodynamic calculation of solidification paths, this study developed a possible mechanism of the Fe-containing phase transformation. Specifically, alloying with Cr accelerated the formation of fivefold symmetry icosahedral quasicrystal θ-Al13(Fe, Cr)4 phases (Al13M4 phases), which then combined with Si atoms in the surrounding melt and favored the formation of polyhedral α-AlCrFeSi phases. Tensile properties of artificial aged alloys were significantly improved by the combination of SRS and alloying with 0.12 wt.% Cr. The yield and ultimate strength increased from ∼254 to ∼293 MPa and ∼288–∼335 MPa, respectively, and the elongation to failure increased from ∼10% to ∼21%. This study may provide guidelines to produce high-ductility Al–Mg–Si alloys by optimizing the Fe-containing phases.

Effect of secondary phase on mechanical and thermal conductivity of Al-Si-xFe-Mg-yCu-Mn die casting alloys

In the present study, effect of secondary phase on mechanical property and thermal conductivity of newly developed high-pressure die-cast Al-6Si-0.3Fe-1.5 Mg(S-1), Al-6.5Si-0.4Fe-1.6 Mg-0.7Cu-0.08Mn(S-2), and Al-8Si-0.5Fe-0.5 Mg-1.5Cu-0.10Mn-0.1Ni(S-3) alloys were investigated. The fraction of α-Al phase and secondary phase has been predicted by thermodynamic simulations. UTS was found to be 307 MPa, 331 MPa and 350 MPa for S-1 ∼ 3 alloys. The thermal conductivities values are 160.3 W/mK, 153.0 W/mK, and 146.0 W/mK for S-1 ∼ 3 alloys. The S-3 alloy has the highest fraction of the secondary phases and as a result of the addition of Fe and Cu is partially precipitated into the Al5Cu2Mg8Si6, Al7Cu2M and β-AlFeSi phases. The mechanical properties of these alloys were found to be directly proportional to the fraction of Si addition as well as secondary phases, whereas thermal conductivity shows the opposite trend. Newly developed S-3 alloys in the present study showed excellent mechanical and thermal conductivity as compared to other Al alloys reported in the literature.

Effect of Cooling Rate on the Microstructure Evolution and Mechanical Properties of Iron-Rich Al-Si Alloy.

The mechanical properties of iron-rich Al–Si alloy is limited by the existence of plenty of the iron-rich phase (β-Al5FeSi), whose unfavorable morphology not only splits the matrix but also causes both stress concentration and interface mismatch with the Al matrix. The effect of the cooling rate on the tensile properties of Fe-rich Al–Si alloy was studied by the melt spinning method at different rotating speeds. At the traditional casting cooling rate of ~10 K/s, the size of the needle-like β-Al5FeSi phase is about 80 μm. In contrast, the size of the β-Al5FeSi phase is reduced to 500 nm and the morphology changes to a granular morphology with the high cooling rate of ~104 K/s. With the increase of the cooling rate, the morphology of the β-Al5FeSi phase is optimized, meanwhile the tensile properties of Fe-rich Al–Si alloy are greatly improved. The improved tensile properties of the Fe-rich Al-Si alloy is attributed to the combination of Fe-rich reinforced particles and the granular silicon phase provided by the high cooling rate of the melt spinning method.