The characterization of Fe-rich phases in a high-pressure die cast hypoeutectic aluminum-silicon alloy

Both microstructural characteristics and fracture behavior of Fe-rich phases in a high-pressure die-cast hypoeutectic Al-Si alloy were investigated. Attention was focused on the morphology and formation mechanism of Fe-rich phases, together with their influence on fracture. Results show that primary Fe-rich phases exhibited in blocky shape precipitated from liquid while secondary Fe-rich phase in a large net shape was distributed along eutectic boundary participating in a ternary eutectic reaction. Through synchrotron X-ray tomography characterization, three Fe-rich phases with different morphologies, i.e., polyhedral shape, fine compact shape and Chinese script-type shape were extracted along the radial direction. Lower slow-shot speed promoted the polyhedral Fe-rich phase to precipitate in slow-shot sleeve while decreased the formation of fine compact and Chinese script-type Fe-rich phases in die cavity. Because of a worse deformation compatibility, polyhedral Fe-rich phases fractured and became stress concentration sources before the failure of the casting. (C) 2020 Published by Elsevier Ltd on behalf of The editorial office of Journal of Materials Science & Technology.