Characterization of silicon phases in spray-formed and extruded hypereutectic Al–Si alloys by image analysis

The silicon phases in the spray-formed and extruded hypereutectic Al–Si alloys (AlSi18, AlSi25 and AlSi35) have been quantitatively evaluated by means of image analysis technique. The influence of silicon content in the alloys, thermal conditions during spray forming of the alloys and hot extrusion of the spray-formed alloys on the size, shape, dispersion and orientation of the silicon phases have been studied and discussed. In general, the silicon phases are greatly refined and uniformly distributed in the spray-formed Al–Si alloys. This improvement in the silicon phases is further facilitated by low thermal input as well as fast cooling conditions during spray forming. The silicon particles in the as-extruded Al–Si alloys appear more homogeneous and regular than those in the as-deposited Al–Si alloys but exhibit a certain amount of anisotropy and a tendency to preferred orientation. The silicon particles, depending on the particle size and shape, may fracture or coarsen during extrusion.     

Morphologies of Si phase and La-rich phase in as-cast hypereutectic Al–Si–xLa alloys

In the present study, the diversified morphologies of Si phase and La-rich phase in as-casted hypereutectic Al–Si–xLa alloys are presented and investigated. The morphological features were examined using conventional optical microscopy and SEM for observations conducted on the optical samples and deep-etched samples, respectively. The results show that primary Si crystals show several morphologies, such as feathery, star-shaped, faceted polygonal, platelet and so on. There are three types of fivefolded Si crystals existing in the present study, fivefold symmetry as radial growth alone: thin-branched, coarse-branched and well-defined star-shaped growing from the preferred growth from the tips of branches. The eutectic Si in unmodified Al–Si alloys appears only in fibrous morphology, while discrete and interconnected coral and rodlike eutectic Si particles were observed in alloys with the addition of La. The La-rich phase also grows into a variety of morphologies, such as needlelike, broken rodlike in pores, spherical, and flat platelet. In optical microscopy, La-rich phase is observed to envelope some small polygonal Si crystals.     

Dry sliding wear behaviour of hypereutectic Al–Si piston alloys containing iron-rich intermetallics

The effect of iron-rich intermetallics on the wear behaviour of Al–Si hypereutectic alloys has been studied. Dry sliding wear tests have been conducted using a pin-on-disk machine under different normal loads of 18, 51, 74 and 100 N and at a constant sliding speed of 0.3 m/s. The addition of 1.2 wt.% Fe to the LM28 alloy increased the wear rate due to the formation of needle beta intermetallics. Introducing 0.6 wt.% Mn to the iron-rich alloy changed the beta intermetallics into the modified alpha phases, and therefore reduced the detrimental effect of iron. TIG welding method as a surface melting process was applied on the iron and manganese containing alloy and led to a fine microstructure and increased the wear resistance.     

Effect of calcium on primary silicon particle size in hypereutectic Al–Si alloys

Abstract

Modification of hypereutectic Al-Sialloy, B390 alloy for the refinement of primary silicon particles, and its effects on tensile and impact properties were examined. Calcium was found to have an effect on the size of primary silicon particles. Primary silicon particle size was refined as calcium content decreased. Control of calcium content by the addition of Ti₂Cl₆ to the melt resulted in successful refinement of primary silicon particles. The minimum size of primary silicon particles was 20.3 μmwitha residual calcium content of 16 ppm. The microstructure was composed of very fine 20.3 μm primary silicon particles, compared to 24.5 μm primary silicon particles obtained using the AlCuP method, previously reported as the most effective method. Refinement of primary silicon particles led to an improvement in the mechanical properties of the alloy, especially elongation.     

Deformation behavior of Al–Si alloy based nanocomposites reinforced with carbon nanotubes

Nanocrystalline Al–Si alloy-based composites containing carbon nanotubes (CNTs) were produced by hot rolling ball-milled powders. During the milling process, the grain size was effectively reduced and the Si element was dissolved in the Al matrix. Furthermore, CNTs were gradually dispersed into the aluminum powders, providing an easy consolidation route using a thermo-mechanical process. The composite sheet containing 3 vol.% of CNTs shows ～520 MPa of yield strength with a 5% plastic elongation to failure.     

Effects of complex modificating technique on microstructure and mechanical properties of hypereutectic Al–Si alloys

In this article, the structure of Al-18Si alloy was modified by thermal-rate treatment technique at 930 °C based on the DSC result. The mechanical properties of Al–18Si alloy were improved remarkable by a complex technique with alloying and thermal-rate treatment. A new treating technique named as complex modificating technique was proposed, and the performance of this technique on Al–18Si–1.5Cu–0.6Mg alloy was investigated. The results show that primary Si can be refined when Al–P master alloy was added into the melt at 770 °C after thermal-rate treatment. Compared with the conventional casting technique by which the melt of alloy was unmodified, better refinement effect can be obtained with the combination of alloying and complex modificating technique: the size of primary Si is decreased from 66 to 16 μm, the tensile strength increased by 75.94% and the brinell hardness by 66.59%. Moreover, the mechanism of the complex modificating technique was also discussed.     

Microstructure and thermal expansion behavior of spray-formed Al–27Si alloy used for electronic packaging

The hypereutectic Al–27Si (mass fraction) alloys are prepared by spray deposition and extrusion. The effect of thermal aging process on the coefficient of thermal expansion (CTE) and microstructure of the Al–27Si alloys are investigated. The results show that the distribution of Si particles in α-Al matrix is uniform, and the primary Si phase grows gradually during the process of thermal aging. The CTE between room temperature to 100 °C increases gradually with the ascending of aging temperature, attributed to the relaxation of residual thermal stress and the coarsening of primary Si phases in the alloys. On the other hand, the CTE increases linearly as the cycling temperature increases up to 500 °C, and the measured values are in good agreement with the Kerner model.     

In-situ EBSD study of deformation behavior of Al–Si–Cu alloys during tensile testing

This study deals with the microstructural aspects of the deformation behavior in Al–Si–Cu alloy A380. This has been carried out with in-situ tensile testing coupled with EBSD analysis. The alloy specimens having different microstructures with two different secondary dendrite arm spacing (SDAS) of 9 μm and 27 μm were produced by the unique gradient solidification method. The study of misorientation distribution and texture evolution was performed with different tools in EBSD analysis. The texture was not significantly affected by deformation in both types of alloy specimens. With increase in the deformation, the microstructures are characterized by degradation of EBSD patterns and generation of substructures including low angle boundaries (LABs) and high angle boundaries (HABs). In both the microstructures with low and high SDAS, the boundaries were concentrated around eutectic phases; however this behavior was more pronounced at higher SDAS. The increase in the fraction of LABs with deformation was much higher in the microstructure with higher SDAS than with lower SDAS. This localized strain concentration was especially attributed to the large and elongated eutectic Si particles and Fe-rich intermetallics. The lower mechanical properties obtained at higher SDAS are the result of inhomogeneous strain distribution in the microstructure.     

Dissolution kinetics of primary silicon in hypereutectic Al–Si melt

The dissolution process of primary silicon particles in Al–18%wt silicon alloy was studied both by a melt overheating experiment and by theoretical analysis. A dissolution model of primary silicon in the melt was established based on atomic diffusion and taking account to interface reaction and curvature of particles. The results show that the theoretical curve agrees with the experimental curve at an overheating temperature of 1100°C. However, there was some deviation at 700°C due to retained silicon clusters in the melt at lower temperature. Therefore, the model is in accord with experiment when not considering the influence of retained silicon clusters.     

Dissolution kinetics of primary silicon in hypereutectic Al–Si melt

The dissolution process of primary silicon particles in Al-18%wt silicon alloy was studied both bya melt overheating experiment and by theoretical analysis. A dissolution model of primary silicon in the melt was established based on atomic diffusion and taking account to interface reaction and curvature of particles. The results show that the theoretical curve agrees with the experimental curve at an overheating temperature of 1100ºC. However, there was some deviation at 700ºCdue to retained silicon clusters in the melt at lower temperature. Therefore, the model is in accord with experiment whennot considering the influence of retained silicon clusters.     

Microstructure and solidification behavior of Cu–Ni–Si alloys

The microstructure and solidification behavior of Cu–Ni–Si alloys with four different Cu contents was studied systematically under near-equilibrium solidification conditions. The microstructures of these Cu–Ni–Si alloys were characterized by SEM and the phase composition was identified by XRD analysis. The phase transition during the solidification process was studied by DTA under an Ar atmosphere. The results show that the microstructure and solidification behavior is closely related to the composition of Cu–Ni–Si alloys. The microstructure of Cu–Ni–Si alloys with higher than 40% Cu content consists of primary phase α-Cu(Ni, Si) and eutectic phase (β₁-Ni₃Si + α-Cu(Ni,Si).When the Cu content is about 40%, only the eutectic phase (β₁-Ni₃Si + α-Cu(Ni,Si)) is present. DTA analysis shows there are three phase transitions during every cooling cycle of alloys with higher than 40% Cu content, but only one for 40% Cu content. Cu–Ni–Si alloy with 40% Cu solidifies by a eutectic reaction, but Cu–Ni–Si alloys with higher than 40% Cu content solidify as a hypoeutectic reaction.     

Use of thermodynamic calculation to predict the effect of Si on the ageing behavior of Al–Mg–Si–Cu alloys

Thermodynamic calculation was employed to predict the influence of Si content on the ageing behavior of Al–Mg–Si–Cu alloys. In addition, experiments were carried out to verify the predictions. The results show that thermodynamic calculation can predict the effect of Si content on the ageing behavior of the studied alloys. This study further proposes that the hardness level of alloys during ageing is directly related to the Si content in the as-quenched supersaturated solution, while the precipitation strengthening effect is directly related to the Mg₂Si level of the alloys.     

Effect of treatment variables on size refinement by phosphide inoculants of primary silicon in hypereutectic Al–Si alloys

Abstract

The effects of phosphorus containing inoculant identity/process history, addition level, addition temperature, and contact time on number density N _A of primary silicon particles in small volumes of cast Al–20 wt-%Si are reported. Inoculation replaces the coarse, branched primary silicon otherwise obtained in the upper part of these castings with a uniform distribution of small polyhedral primary silicon particles. The inoculants tested increased in effectiveness in the sequence: die pressed and heat treated Al–Fe–P; die pressed Al–Fe–P; extruded Al–Cu–P; and Al–Fe–P prepared by a proprietary route. This last inoculant gave a maximum N _A at 200 ppm addition level in this volume of melt for a contact time of 10 min at 800°C, and at 10 min contact time for an addition level of 100 ppm at this temperature. An addition temperature of 850°C produced a small reduction in N _A, compared with 750 or 800°C. The significance of these findings is discussed in the context of previously published work and possible mechanisms leading to less effective inoculation at high addition levels and extended contact times.     

Structure factors of modified liquid Al–Si alloys

The structure factor and the coordination numbers of liquid Al–Si alloys with different Si content have been measured by a high temperature X-ray diffractometer. Radial distribution functions (RDFs), the nearest atomic distance and the coordination numbers of eutectic Al–Si alloys before and after being modified with Sr and Sb were studied. The RDFs of the liquid alloy were decomposed by five Gaussian peaks. The results show that a Si–Si covalent bond exists in the liquid of eutectic and hyper-eutectic alloys. Sr in the liquid Al–Si has a capability to weaken the covalent bonds of Si–Si, suppressing the nucleation of the eutectic silicon phase. On the other hand, Sb in the liquid Al–Si increases the order degree of Si atoms, decreasing the supercooling degree of the nucleation and promoting the nucleation of eutectic silicon.     

Modification of eutectic silicon in Al–Si alloys

The mechanical properties of Al–Si alloys are strongly related to the size, shape and distribution of eutectic silicon present in the microstructure In order to improve mechanical properties, these alloys are generally subjected to modification melt treatment, which transforms the acicular silicon morphology to fibrous one resulting in a noticeable improvement in elongation and strength. Improper melt treatment procedures, fading and poisoning of modifiers often result in the structure which is far from the desired one. Hence it is essential to assess the effectiveness of melt treatment before pouring. A much investigated reliable thermal analysis technique is generally used for this purpose. The deviation from the standard curve in thermal analysis helps in assessing the level of refinement of the Si structure. In the present review an attempt is made to discuss various aspects of modification, including mechanism, interaction of defects and non-destructive assessment by thermal analysis.     

Deformation and fracture in Al–Li-base alloys

Abstract

Aluminium–lithium-base alloys are of considerable interest because of their low density and high modulus. However, they have been shown to have low ductility and poor fracture toughness. This has been attributed to a variety of factors, including intense shear band formation, segregation to grain boundaries, and weakened grain boundaries due to precipitation and precipitate-free zones. The authors have investigated the deformation structures observed in binary and more complex commercial alloys. As would be expected, considering the microstructure of the alloys, extensive strain localization and shear band formation occurs in these alloys. However, it is shown that the commercial alloys are less sensitive to strain localization than the model binary alloy systems investigated. The stresss–train behaviour has been investigated. The alloys exhibit jerky flow, which is indicative of negative strain rate sensitivity, and strain rate change tests showed this to be the case. This is consistent with the deformation structures observed. The effect of weakened grain boundaries due to precipitation and precipitate-free zones has been studied by comparing the fracture characteristics of aged and unaged material. It is shown that the mode of failure is identical under appropriate conditions. It is concluded that segregation to grain boundaries is the major cause of the lower ductility and toughness of Al–Li alloys. This possibility has been investigated using in situ fracture surface analysis techniques. Results are presented on grain boundary segregation, and methods of reducing its influence on fracture behaviour are indicated.

MST/570     

Structure factors of modified liquid Al–Si alloys

The structure factor and the coordination numbers of liquid Al–Si alloys with different Si content have been measured by a high temperature X-ray diffractometer. Radial distribution functions (RDFs), the nearest atomic distance and the coordination numbers of eutectic Al–Si alloys before and after being modified with Sr and Sb were studied. The RDFs of the liquid alloy were decomposed by five Gaussian peaks. The results show that a Si–Si covalent bond exists in the liquid of eutectic and hyper-eutectic alloys. Sr in the liquid Al–Si has a capability to weaken the covalent bonds of Si–Si, suppressing the nucleation of the eutectic silicon phase. On the other hand, Sb in the liquid Al–Si increases the order degree of Si atoms, decreasing the supercooling degree of the nucleation and promoting the nucleation of eutectic silicon.     

The electrochemical properties of melt-spun Al–Si–Cu alloys

Melt spinning was used to prepare Al_75−XSi₂₅Cu_X (X = 1, 4, 7, 10 mol%) alloy anode materials for lithium-ion batteries. A metastable supersaturated solid solution of Si and Cu in fcc-Al, α-Si and Al₂Cu co-existed in the alloys. Nano-scaled α-Al grains, as the matrix, formed in the as-quenched ribbons. The Al₇₄Si₂₅Cu₁ and Al₇₁Si₂₅Cu₄ anodes exhibited initial discharge specific capacities of 1539 mAh g⁻¹, 1324 mAh g⁻¹ and reversible capacities above 472 mAh g⁻¹, 508 mAh g⁻¹ at the 20th cycle, respectively. The specific capacities reduced as the increase of the Cu content. AlLi intermetallic compound was detected in the lithiated alloys. It is concluded that the lithiation mechanism of the Al–Si-based alloys can be affected by the third component. The structural evolution and volume variation can be mitigated due to the formation of non-equilibrium state and the co-existence of nano-scaled α-Al, α-Si, and Al₂Cu for the present alloys.     

Influence of Si content on thermal expansion characteristic of Al–Si alloys

ABSTRACT

The objective of this study was to find out how Si precipitation affects the linear thermal expansion behaviors of Al–Si alloys with various Si content. These Al–Si alloys were manufactured by gravity casting using 99.98?wt-% pure Al and 98.5?wt-% Si pellets. Solution treatment was carried out at 530°C for 10 h for each specimen. As-quenched specimens were subjected to microstructure observation and linear thermal expansion analysis. Si precipitation and additional linear thermal expansion occurred at lower temperature when Si content was increased to 9.5?wt-%. The activation energy of Si precipitation was also lower when Si content was higher. Eutectic Si reduced diffusion distance and acted as a nucleation site of dissolved Si atoms in the Al matrix during aging. These Si phases decreased Si precipitation temperature and activation energy of Si precipitation.