Location of Repository

Rapidly Solidified Aluminium-High Silicon Alloys

By Faraj D.F. Alshmri


Aluminium silicon alloys are the most used raw material for automotive applications. One of the main limitations on using aluminium high silicon alloys is the formation of coarse brittle phases under conventional solidification conditions. However, rapid solidification processing (RS) is very effective in limiting the coarsening of primary silicon due to high cooling rate. \ud Aluminium high silicon alloys can be processed by different RS methods. However, melt spinning is the most familiar of all RS commercial methods. \ud Rapid solidification is a material production route. It does not give the final shape. Rapidly solidified materials require consolidation after solidification. Moreover, consolidation requires mechanical and/or thermal treatment. These treatments may degrade the microstructure. Also hot extrusion may be used as a final step, which may cause deterioration of the initially useful properties due to hot working. In general, although rapid solidification may suppress the coarsening of Si during solidification, the Si particulates may still coarsen during the subsequent thermo-mechanical treatment due to heat effect during consolidation and extrusion. \ud In the present work characterisation of the material at various stages of production has been carried out and understanding of the metallurgical phenomena involved. Several alloy variants were examined. Coarsening behaviour of the Silicon particles and hardness tests were carried out. Wear properties of the alloys have been studied under dry sliding conditions against a steel ball bearing. Analyses and observation of the wear surfaces and wear mechanisms of these alloys are discussed. Wear of RS materials was compared with piston material A390 made by casting. \ud Degassing and HIPping at 400 °C for 12 hrs prior to HIPping seems to be the optimum the degassing is effective whilst avoiding excessive coarsening of the silicon particles. \ud Alloy number RSP461 (Al 21Si 3.9Cu 1.2Mg 2.4Fe 1.4Ni 0.4Zr) shows excellent wear resistance due to its fine microstructure

Publisher: University of Leicester
Year: 2010
OAI identifier: oai:lra.le.ac.uk:2381/9952

Suggested articles



  1. (2007). A Parametric Study of the Relationship Between Microstructure and Wear Resistance of Al–Si alloys "
  2. (2001). A Perspective on the Development of Rapid Solidification and Nonequilibrium Processing and its Future,"
  3. (1991). Al-20Si-Fe Osprey Preform and its Development During Subsequent Processing,"
  4. (2003). An Overview of the Development of Al-Si Alloy Based Material for Engine Applications,"
  5. (1987). Analysis of Metallurgical Failures.
  6. (2006). and A.Sakakibara, "Effects of a Small Addition of Cu or Ge on the Microstructure and Mechanical Property of an Al-Si Alloy,"
  7. (1990). and J.A.G.Kals, "Formability of Recycled Aluminium- Advantages of a Rapid Solidification Process,"
  8. (1987). BAI and S.K.Biswas, "Characterization of Dry Sliding Wear of Al-Si Alloys,"
  9. (2001). Characterization Investigations of Melt Spun Ternary Al-xSi-3.3Fe (x=10, 20 wt.%) Alloys,"
  10. (1980). Characterization of Al-Si-Alloys Quenched from the Melt,"
  11. (1987). Characterization of Rapidly Solidified Aluminium-Silicon Alloy,"
  12. (1991). Characterizationof Rapidly Solidified Structures of Al-6Fe-3MM,"
  13. (2005). Chemical Leaching of Rapidly Solidified Al-Si Binary Alloys,"
  14. (1993). Coarsening Behaviour of Primary Si in Melt-Spun Al-22 wt.%Si,"
  15. (2007). Consolidation and Mechanical Properties of Near-Net-Shape Al-21wt.%Si Component Fabricated by Plasma Spray Forming,"
  16. (1985). Contact Mechanics. Cambridge UK:
  17. (2001). Corrosion of Spray Formed Al-Si-Cu Alloys in Ethanol Automobile Fuel,"
  18. (2005). Crystallographic Orientatrion Spray Formed Hypereutectic Aluminium Silicon Alloys,"
  19. (1984). Cutting Edge Tecnology,"
  20. (1991). Degassing of Al-Si-X Powders Assisted by Flushing with Argon or Nitrogen,"
  21. (1996). Degassing of Gas Atomised Al-Li Base Alloy Powders Part1: Mass Spectrometry Studies,"
  22. Development of Aluminium Powder Metallurgy Composites for Cylinder Liners,"
  23. (2004). Dispersion Strengthening in a Hypereutectic Al-Si Alloy Prepared By Extrusion of Rapid Solidified Powder,"
  24. (2000). Dry Sliding Wear in High Density Fe-2%Ni Based P/M Alloys,"
  25. (1999). Effect of Alloying Elements and Degassing Pressure on the Structure and Mechanical Properties of Rapidly Solidified Al-20Si-Fe-X (X=Cr, Zr, or Ni) alloys,"
  26. (1996). Effect of Element Additions on Wear Property of Eutectic Aluminium-Silicon Alloys,"
  27. (1986). Effect of Load on dry Sliding Wear Of Aluminum-Silicon Alloys,"
  28. (1998). Effect of Rapid Solidification on the Structures and Mechanical Properties of AlSi Based Casting Alloys,"
  29. (2004). Effect of Si Content on the Dry Sliding Wear Properties of Spray-Deposited Al-Si Alooys,"
  30. (1992). Effect of SiC Particulate Reinforcement on the Dry Sliding of Aluminium-Silicon Alloys (A356),"
  31. (2006). Effect of Silicon on Strength and Fracture Surfaces of Aluminium-Silicon Casting and Heat Treated Alloys,"
  32. (2003). Effect of Solution Heat Treatment and Additives on the Microstructure of Al-Si (A413.1) Automotive Alloys,"
  33. (1998). Elements of Rapid Solidification: Fundamentals and Applications"
  34. (2005). Engineering Tribology. Cambridge:
  35. (1991). Extrusion of Metal Powders,"
  36. (2006). Field Assisted Sintering Consolidation of Al-Si-Fe-X Alloy Powder/Flakes Produced Through Air Atomization/Melt Spinning,"
  37. (1965). Friction and wear of Materials.
  38. (2000). Fundamental Aspects of Hot Isostatic Pressing: An Overview,"
  39. (2003). Fundamental Wear Mechanism of Metals,"
  40. (2001). Haque and A.Sharif, "Study on Wear Properties of Aluminium-Silicon Piston Alloy,"
  41. (2004). Hardness and Microstructural Characteristics of Rapidly Solidified Al-8-16 wt. % Alloys,"
  42. (2003). Hardness Evaluation of Al-12Si0.5Sb Melt Spun Ribbons,"
  43. (1998). High Strength Aluminum Casting Alloy for H igh Temperature Applications,"
  44. (2006). HRTEM Characterization of Melt-Spun Al-Si-Cu-Mg Alloys Solidified At Different Rates,"
  45. (2003). Hypereutectic RS/PM Al-Si-X Alloys,"
  46. (1997). Influence of Microstructure on Mechanical Properties of Hypereutectic Al-Si Alloys,"
  47. (2005). Influence of Silicon (wt.%) and Heat Treatment on Abrasive Wear Behaviour of Cast Al-Si-Mg Alloys,"
  48. (2003). Mechanical and Microstructural Characterisation of Cylinder Liners,"
  49. (1994). Mechanical Properties of a Rapidly Solidified Al-Si-Ni-Mn Alloy,"
  50. (1997). Mechanical Properties of Rapidly Solidified Ribbons of Some Al Si Based Alloys,"
  51. (2002). Mechanical Stir Casting of Aluminium Alloys from the Mushy State: Process, Microstructure and Mechanical Properties,"
  52. (1994). Meltspun Aluminium Successful in Racing Piston,"
  53. (1985). Metallurgy for Engineers.
  54. (1997). Mg Effects on the Eutectic Structure and Tensile Properties of Al-Si-Mg Alloys,"
  55. (2004). Microstructural Characterization of As-quenched and Heat treated Al-Si-Mg Melt Spun Ribbons,"
  56. (2006). Microstructural Evolution During Annealing of a Rapidly Solidified Al-12Si Alloy,"
  57. (2001). Microstructural Evolution in Rapidly Solidified Al-Cu-Si Ternary Alloys,"
  58. (1991). Microstructural Features and Final Mechanical Properties of the Iron-Modified Al-20Si-3Cu-1Mg Alloy Product Processed from Atomized Powder,"
  59. (1972). Microstructure and
  60. (2001). Microstructure and Mechanical Properties of Al-Si Alloys Produced by Spray Forming Process,"
  61. (2008). Microstructure and Mechanical Properties of Hypereutectic Al-Si Alloys Fabricated by Spray Casting,"
  62. (1998). Microstructure and Mechanical Properties of Rapid Solidified Hypereutectic Al-Si and Al-Si -Fe Alloys,"
  63. (2003). Microstructure and Mechanical Properties of Spray Deposited Al-Si-Fe-Cu-Mg alloy Containg Mn,"
  64. (2002). Microstructure and Phase Formation in Spray Deposited Al-18%Si-5%Fe-1.5%Cu Alloy,"
  65. (1999). Microstructure and Properties of High Strength Aluminium Alloys Subjected to Rapid Solidificaton Processing,"
  66. (2001). Microstructure Characteristics of a Hypereutectic Al-Si Alloy Manufactured by Rapid Solidification/Powder Metallurgy Process,"
  67. (2001). Microstructure Development During Rapid Solidification,"
  68. (2001). Microstructure of Rapidly Solidified Al20%Si Alloys Powders,"
  69. (1998). Microstructures and Mechanical Properties of Al-20Si-xFe (x=3, 5, 7) Alloys Manufactured by Rapid Solidification Processing,"
  70. (1994). Modern Automotive Technology. South Holland, Illinois,: The Goodheart Willcox Co.,
  71. (1986). Morphology and Mechanical Properties of Melt-Spun and Conventionally Cast Aluminium, AlMg and AlSi Alloys Before and after Hot Extrusion,"
  72. (2000). New Directions in Aluminum-Based P/M Materials for Automotive Applications,"
  73. (1999). Nonequilibrium Microstructure of Hypereutectic Al-Si Alloy Solidified Under Superhigh Pressure,"
  74. (2006). On the Way to Ultra-Light Piston,"
  75. (1979). Powder Metallurgical Processing of Rapidly Solidified Al-Si and Al-Zn-Mg Alloys,"
  76. (2006). Precipitation Behavior of Zirconium Compounds in Zr Bearing Al-Mg-Si Alloy,"
  77. (1997). Precipitation Behaviour of Al Mg Si Alloys with High Silicon Content,"
  78. (1996). Precipitation Strengthening and Mechanicl Properties of Hypereutectic P/M Al-Si-Cu-Mg Alloys Containing Fe and Ni.,"
  79. (1995). Prediction Versus Experimental Fact in the Formation of Rapidly Solidified Microstructure,"
  80. (1997). Processing, Microstructure and Fracture Behaviour of a Spray Atomized and Deposited Aluminium Silicon Alloy,"
  81. (2001). Production and Structure of Rapidly Solidified Al-Si Alloys,"
  82. (1992). Production of Al-(12-25) wt% Si Alloys By Rapid Solidification: Melt Spinning Versus Centrifugal Atomization,"
  83. (2006). Progression of Wear in the Mild Wear Regime of an Al-18.5% Si (A390) Alloy,"
  84. (1997). Property Improvement in Al-Si Alloys through Rapid Solidification Processing,"
  85. (1991). Rapid Pressure Solidification in an Al-Si Alloy,"
  86. (1982). Rapid Solidification of Metals and Alloys. London: The Institution of Metallurgists,
  87. (1992). Rapid Solidification Processing with Specific Application to Aluminium Alloys,"
  88. (1983). Rapid Solidification Technology Source Book," American Society for Metals,
  89. (1982). Rapid Solidification,"
  90. (1993). Rapid Solidified Alloys,"
  91. (1986). Rapid Solidified Powder Aluminium Alloys,"
  92. Rapidly solidified Al-SiMg Alloy,"
  93. (1984). Rapidly Solidified Alloys Made by Chill Block Melt Spinning Processes,"
  94. (2002). Rapidly Solidified Hypereutectic Al-Si Alloys Prepared by Powder Hot Extrusion," Transaction Nonferrous Metals Soc.
  95. (2000). Recent Development in Aluminium Alloys for the Automotive Industry,"
  96. (1983). Scanning Electron Microscopy Study of Worn Al-Si Alloy Surfaces,"
  97. (1996). Semi-Solid Processing of Novel MMCs Based on Hypereutectic Aluminium-Silicon Alloys,"
  98. (1998). Sliding Wear Behavior of Some Al-Si Alloys: Role of Shape and Size of Si Particles and Test Conditions,"
  99. (1994). Solidification Behaviour of an Al-6Si Alloy during Spray Atomization and Deposition,"
  100. (1994). Solute Trapping of Group 3,4,5 Elements in Silicon by an Aperiodic Stepwise Growth Mechanism,"
  101. (1994). Spray Formed Aluminum Alloy Finds Engine Role,"
  102. (1987). State of the Art of Research and Development in Rapid Solidification Technologies in Japan,"
  103. (1982). Structural Inhomogeneties of AlSi Alloys Repidly Quenched from the Melt,"
  104. (1978). Structure and Mechanical Properties of Rapidly Solidified Aluminium Alloys "
  105. (1999). Structure and Properties of Rapidly Solidified Al Rich Al-Mn-si Alloys,"
  106. (1986). Structure and Stability of Rapidly Solidified Al-Si base Alloys,"
  107. (2000). Studies on Wear Characteristics of Al-Fe-V-Si Alooys.,"
  108. (2002). Study on the Extruded Structure of Rapidly Solidified Hypereutectic,"
  109. (2004). Surface Roughness and Tool Wear During Single Point Diamond Turning of Rapidly Solidified Aluminium Alloys,"
  110. (1976). The Effect of Cr, Co, and Sr Additions on The Strength of an Al-35%Si Powder Alloy,"
  111. (2004). The Effect of Isothermal Mechanical Stirring on an Al-Si Alloy in the Semisolid Condition,"
  112. (2005). The Effect of Silicon Content on Long Crack Fatigue Behaviour of Aluminium Silicon Piston Alloys At Elevated Tmperature,"
  113. (1997). The Effects of Cr and Zr Addition on the Microstructure and Mechanichal Properties of Rapidly Solidified Al20Si-5Fe Alloys,"
  114. (2003). The Microstructure and Mechanical Properties of Spray Deposited Hypereutectic Al-Si-Fe Alloy,"
  115. (1996). The Science and Engineering of Materials:
  116. (2005). The Science and Technology of Materials in Automotive Engines. Cambridge England:
  117. (1984). The Status of Rapid Solidification of Alloys in Research and Application "
  118. (2000). Understanding How components Fail. Ohio,USA:
  119. (1996). Vacuum Degassing of Aluminium Alloys,"
  120. (1979). Wear Characteristics of As-Cast Binary Aluminum-Silicon Alloys,"
  121. (1987). Wear in Al-Si Alloys Under Dry Sliding Conditions,"
  122. (1989). Wear Mechanisms in Ferrous Alloys," Nuclear Instruments and Methods
  123. (1971). Wearing Behavior of Binary Al-Si Alloys with cast iron,"

To submit an update or takedown request for this paper, please submit an Update/Correction/Removal Request.