Morphological Evolution of Fe-Rich Phases in the AlSi9Cu3Mg0.19(Fe) Alloy with the Addition of Minor Mn and Cr

doi:10.1007/s40195-017-0688-y

Abstract

Abstract:

The morphological evolution of Fe-rich phases in the AlSi₉Cu₃Mg_0.19(Fe) alloy has been investigated with various contents of Fe, Mn, and Cr. The results show that coarse Chinese script Fe-rich phases appear in the alloy with 0.6 wt% Fe combined with trace Mn, while the blocky Fe-rich phases appear combined with trace Cr. Under the coexistence of trace Mn and Cr, a large number of fine Chinese script Fe-rich phases could be visible in the low iron-bearing AlSi₉Cu₃Mg_0.19(Fe) alloy (0.60 wt%). At high Fe level (1.30 wt%), numerous Fe-rich phases with hexagonal morphologies are observed with the trace Cr, while fish-bone and pentagonal morphologies of Fe-rich phases could be simultaneously observed with the addition of both Mn and Cr. The results reveal that the trace Mn and Cr promote the morphological evolution of Fe-rich phases. The morphology evolution mechanism of Fe-rich phases has been discussed by using the atom radius and electronegativity differences of Fe, Mn, and Cr.

Key words: AlSi₉Cu₃Mg_0.19(Fe) alloy, Fe-rich phase, Sludge factor, Microalloying, Electronegativity differences

Zhi-Qiang Qiu, Xiang-Chen Meng, Qiu-Hong Yuan, Xiao-Shu Zeng, Xi-Xin Rao, Yan Ding, Lan Luo, Yong Liu. Morphological Evolution of Fe-Rich Phases in the AlSi₉Cu₃Mg_0.19(Fe) Alloy with the Addition of Minor Mn and Cr[J]. Acta Metallurgica Sinica (English Letters), 2018, 31(6): 629-640.

Figures/Tables 15

Table 1 Chemical composition (wt%) and SF of AlSi9Cu3Mg0.19(Fe) alloys with the addition of minor Mn and Cr

Alloys	Fe	Mn	Cr	SF
Alloy 1	0.60	0.10	0	0.80
Alloy 2		0	0.10	0.90
Alloy 3		0.10	0.10	1.10
Alloy 4	1.30	0.10	0	1.50
Alloy 5		0	0.10	1.60
Alloy 6		0.10	0.10	1.80

Fig. 1 OM images of AlSi9Cu3Mg0.19(Fe) alloys with 0.6 wt% Fe and a 0.1 wt% Mn, b 0.1 wt% Cr, c 0.1 wt% Mn, 0.1 wt% Cr; with 1.3 wt% Fe and d 0.1 wt% Mn, e 0.1 wt% Cr, f, g 0.1 wt% Mn, 0.1 wt% Cr. The red arrows in a-g show the coarse Chinese script, blocky, fine Chinese script, needle-like, hexagonal morphologies, fish-bone, and pentagonal morphologies of Fe-rich phases, respectively

Fig. 2 SEM images and EDS results (insets) of AlSi9Cu3Mg0.19(Fe) alloys with 0.6 wt% Fe and a 0.1 wt% Mn, b 0.1 wt% Cr, c 0.1 wt% Mn, 0.1 wt% Cr; with 1.3 wt% Fe and d 0.1 wt% Mn, e 0.1 wt% Cr, h 0.1 wt% Mn, 0.1 wt% Cr. f and g are the linear scanning curves of elements on needle-like phase d, hexagonal phase e (marked by the red two-way arrows)

Fig. 3 Schematic illustration of the evolution of Fe-rich phases in the AlSi9Cu3Mg0.19(Fe) alloy

Table 2 EDS results of phases in the AlSi9Cu3Mg0.19(Fe) alloy (wt%)

Alloys	Al	Si	Cu	Fe	Mn	Cr
Alloy 1	60.2	15.7	1.4	21.9	0.8	-
Alloy 2	55.5	16.2	2.8	25.0	-	0.5
Alloy 3	63.1	7.8	5.9	19.0	1.5	2.7
Alloy 4	64.4	12.7	1.7	20.5	0.8	-
Alloy 5	59.6	7.9	4.6	24.1	-	3.9
Alloy 6	54.2	8.5	11.0	24.4	1.2	0.8

Fig. 4 TEM micrograph of the Alloy 5: a bright-field image of the hexagonal Fe-rich phase, b the corresponding EDS spectrum

Fig. 5 XRD patterns of the AlSi9Cu3Mg0.19(Fe) alloy

Fig. 6 Volume fraction and size (length) of Fe-rich phases in the AlSi9Cu3Mg0.19(Fe) alloy with a 0.6 wt% Fe, b 1.3 wt% Fe

Fig. 7 Volume fraction and size (length) of Fe-rich phases in the AlSi9Cu3Mg0.19(Fe) alloy as function of the sludge factor

Fig. 8 Roundness of Fe-rich phases as function of the sludge factor in the AlSi9Cu3Mg0.19(Fe) alloy

Table 3 Roundness of Fe-rich phases in the AlSi9Cu3Mg0.19(Fe) alloy

Alloys	Fe (wt%)	Mn (wt%)	Cr (wt%)	SF	Roundness
Alloy 1	0.60	0.10	0	0.80	1.65
Alloy 2		0	0.10	0.90	1.58
Alloy 3		0.10	0.10	1.10	1.82
Alloy 4	1.30	0.10	0	1.50	2.00
Alloy 5		0	0.10	1.60	1.70
Alloy 6		0.10	0.10	1.80	1.97

Fig. 9 Microhardness profiles over the phases in the AlSi9Cu3Mg0.19(Fe) alloy: a needle-like Fe-rich phases in the Alloy 4 (1.3 wt% Fe, 0.1 wt% Mn), b hexagonal Fe-rich phases in the Alloy 5 (1.3 wt% Fe, 0.1 wt% Cr)

Table 4 Atom radius and electronegativity of Al, Fe, Mn and Cr

Element	Atom radius (?)	Electronegativity	Electronegativity difference with Fe
Al	1.43	1.61	0.22
Fe	1.26	1.83	-
Mn	1.27	1.55	0.28
Cr	1.28	1.66	0.17

Table 5 Interaction intensity (W) of all systems

Systems	Interaction intensity, W
Al-Fe	1.11
Al-Mn	0.73
Al-Cr	0.63
Fe-Mn	0.49
Fe-Cr	0.19
Mn-Cr	0.08

Fig. 10 Schematic illustration of the morphology evolution mechanism of Fe-rich phases in the AlSi9Cu3Mg0.19(Fe) alloy with and without microalloy: a without microalloy, b Mn, c Cr, d Mn, Cr; e electronegativity difference and inset is the atom radius of element

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Morphological Evolution of Fe-Rich Phases in the AlSi₉Cu₃Mg_0.19(Fe) Alloy with the Addition of Minor Mn and Cr

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