Controlling the Fe-intermetallic phases and mechanical properties of secondary Al-9Si-1Fe alloy with Cr and Mn additions

doi:10.1016/j.jmst.2024.04.014

Abstract

Abstract: In secondary Al-Si based alloys, microalloying with Mn and Cr can modify harmful platelet-type Al_xFe_ySi_z intermetallic phases to less detrimental α-Al_x(Fe, Mn, Cr)_ySi_z phase (script or polygonal morphologies). However, the α-Al_x(Fe, Mn, Cr)_ySi_z phase morphology, phase composition and the addition of Fe-correcting elements can be influenced by solidification conditions. Therefore, this research is aimed to highlight the morphological evolution and mechanisms of α-Al_x(Fe, Mn, Cr)_ySi_z phase in a Cr added Al-9 %Si-1 %Fe-0.2 %Cr (all weight percentage thereafter, unless otherwise stated) alloy with varying Mn concentrations (0.25 %, 0.5 %, and 0.8 %). Microstructure evolution of Fe intermetallic phases is investigated under different casting conditions using a wedge-shaped die, Cu-chill block and melt quenching experiments. Thermodynamic simulations have been performed using CALculation of PHAse Diagrams (CALPHAD) method and compared with the experimental results for phase composition and formation temperatures of α-Al_x(Fe, Mn, Cr)_ySi_z phase. The results indicated that for 0.25Mn-0.2Cr addition to Al-9Si-1Fe alloy, compact morphology containing polygonal phases are formed in Cu-chill casting, while the wedge castings predominantly show a mixed structure with platelets and script type morphologies. Tensile tests revealed a higher elongation value of 6.6 % for mixed structure with platelet and script phases, which is decreased to 4.2 % for polygonal phases in Al-9Si-1Fe-0.2Cr-0.25Mn alloy. This study highlights the importance of solidification conditions on morphologies of Fe-intermetallic phases and the mechanical properties by comparing selected literature relevant to high pressure die-casting process.

Key words: Al-Si alloys, CALPHAD, Fe-intermetallic phases, Mechanical properties, Solidification

Nagasivamuni Balasubramani, Michael Moodispaw, Alan A Luo. Controlling the Fe-intermetallic phases and mechanical properties of secondary Al-9Si-1Fe alloy with Cr and Mn additions[J]. J. Mater. Sci. Technol., 2025, 206: 135-152.

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