Intrinsic and Extrinsic Effects of Microstructure on Properties in Cast Al Alloys

The metallurgy of cast aluminum alloys has always been considered to be different from that of wrought alloys. Metallurgists have been taught that pores are intrinsic in cast aluminum alloys and that mechanical properties in cast aluminum alloys are controlled by dendrite arm spacing, the presence of Fe-bearing particles, and the size of Si particles in Al-Si alloys, which fracture and debond during deformation, leading to premature failure. Whether these effects are intrinsic or extrinsic, i.e., mere correlations due to the structural quality of castings, is discussed in detail. Ideal properties are discussed, based on findings presented mostly in physics literature. Pores and hot tears in aluminum castings are extrinsic. Moreover, the effect of dendrite arm spacing on elongation, precipitation, and subsequent fracture of beta-Al5FeSi platelets, and finally Si particle fracture and debonding are all extrinsic. A fundamental change in how we approach the metallurgy of cast aluminum alloys is necessary.