Formation of iron-bearing intermetallics in aluminum-silicon casting alloys

The formation of iron-bearing intermetallics in the 413 type of aluminum alloys was investigated comprehensively. Both synthetic and commercial 413 alloys were studied with iron concentrations in the range of 0.4-1.2 wt. % and manganese up to 0.5 wt.%. The effects of cooling rate during solidification and of melt chemistry on the morphology of iron intermetallic phases were determined. Image analysis was used to quantify the intermetallic size, volume fraction, and number, as a function of both melt chemistry and cooling rate. The total volume fraction of intermetallic compounds in these alloys was related to cooling rate by an exponential equation.;The kinetics of both dissolution of intermetallics on melting, and of re-formation on cooling of the liquid were investigated by means of quenching experiments. Quantitative evaluation of intermetallic size and number revealed that the change in volume fraction of intermetallics in the liquid state is controlled by nucleation.;The effect of settling time and the rate of gravity segregation of intermetallic compounds in a stagnant liquid metal were investigated. It was found that, in the absence of convection, settling obeys Stokes' law with the terminal velocity reached at very short times and very close to the melt surface.;Strontium was used to modify or eliminate the iron-intermetallics. (Abstract shortened by UMI.)...