Effect of intensive melt shearing on the formation of Fe-containing intermetallics in LM24 Al-alloy

Fe is one of the inevitable and detrimental impurities in aluminium alloys that degrade the mechanical performance of castings. In the present work, intensive melt shearing has been demonstrated to modify the morphology of Fe-containing intermetallic compounds by promoting the formation of compact α-Al(Fe,Mn)Si at the expense of needle-shaped β-AlFeSi, leading to an improved mechanical properties of LM24 alloy processed by MC-HPDC process. The promotion of the formation of α -Al(Fe, Mn)Si phase is resulted from the enhanced nucleation on the well dispersed MgAl 2O 4 particles in the melt. The Fe tolerance of LM24 alloy can be effectively improved by combining Mn alloying and intensive melt shearing