The role of fluid flow and intermetallic phases in the formation of the primary Al-phase in AlSi alloys

Abstract

In secondary AlSi alloys, the presence of small amounts of Fe causes the formation of intermetallic phases, which have a negative effect on mechanical and physical properties of castings. To understand the effect of fluid flow on the microstructure and intermetallic phases, Al-5/7/9 wt pct Si 0.2/0.5/1.0 wt pct Fe alloys have been directionally solidified under defined thermal (gradient 3 K/mm, solidification velocity 0.04 mm/s) and fluid flow (rotating magnetic field 6 mT) conditions. The primary α-Al phase and intermetallic phases were studied using light microscopy and SEM with EDX. The influence of fluid flow and intermetallic phases (β- Al5FeSi) on microstructure was characterized by changes of primary and secondary dendrite arm spacing and specific surface area of the dendrites. We observe a pronounced effect of flow on the length of the intermetallic precipitates, a macro-segregation Fe and Si and even small amounts of iron and thus intermetallics reduce possible effects of flow on microstructural parameters.