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.

Modification of eutectic silicon in Al-Si alloys

Friction stir welding (FSW), a highly efficient solid-state joining technique, has been termed as “green” technology due to its energy efficiency and environment friendliness. It is an enabling technology for joining metallic materials, in particular lightweight high-strength aluminum and magnesium alloys which were classified as unweldable by traditional fusion welding. It is thus considered to be the most significant development in the area of material joining over the past two decades. Friction stir processing (FSP) was later developed based on the basic principles of FSW. FSP has been proven to be an effective and versatile metal-working technique for modifying and fabricating metallic materials. FSW/FSP of aluminum alloys has prompted considerable scientific and technological interest since it has a potential for revolutionizing the manufacturing process in the aerospace, defense, marine, automotive, and railway industries. To promote widespread applications of FSW/FSP technology and ensure t...

Recent Advances in Friction Stir Welding/Processing of Aluminum Alloys: Microstructural Evolution and Mechanical Properties

Microstructure, precipitates and hardness of selectively laser melted AlSi10Mg alloy before and after heat treatment

Assessment of different techniques for quantification of α-Al(FeMn)Si and β-AlFeSi intermetallics in AA 6xxx alloys

Comparative study of performance comparison of AlSi10Mg alloy prepared by selective laser melting and casting

The Al-Fe-Si intermetallics present in a commercial cast 6201 electrical conductor alloy have been studied using high resolution electron microscopy. The β-Al5FeSi phase is highly faceted and contains multiple (001) growth twins parallel to the growth direction. The α-Al8Fe2Si phase which forms in a Chinese script morphology has a nonfaceted interface with the aluminum matrix and exhibits no growth twinning. Formation of the β phase is believed to occurvia a peritectic decomposition of α-Al8Fe2Si at 612 °C. Observations made by transmission electron microscopy (TEM) support this hypothesis. When 30 ppm strontium is added to this alloy, the α phase is stabilized and very little β-Al5FeSi appears in the microstructure. A silicon-rich layer is found around the α-phase particles. It is proposed that strontium adsorbs to the α-phase interface, and in so doing, the diffusion of silicon into the α phase, necessary for its transformation to β, is prevented.

Electron microscope study of Al-Fe-Si intermetallics in 6201 aluminum alloy

A transmission electron microscopy (TEM) study of a 6201 aluminum alloy to which controlled strontium additions were made has revealed important differences compared to the same alloy free of strontium. In the as-cast state, strontium favors the formation of α-AlFeSi (Al8Fe2Si) rather than β-AlFeSi (Al5FeSi) phase, resulting in a greater quantity of excess silicon present in the strontium-treated alloy. During heat treatment, the excess silicon allows a greater density of finer β″-Mg2Si precipitates to form, leading to increased tensile strength values and increased electrical resistivity. Strontium also retards the growth of the precipitates formed during heat treatment and inhibits formation of the equilibrium β-Mg2Si phase. As a result, the strontium-treated alloy exhibits a resistance to overaging.

M. H. Mulazimoglu

Papers

Electron microscope study of Al-Fe-Si intermetallics in 6201 aluminum alloy

The effect of strontium on the Mg2Si precipitation process in 6201 aluminum alloy