Effects of Be, Sr, Fe and Mg interactions on the microstructure and mechanical properties of aluminum based aeronautical alloys

The present work was carried out on a series of heat-treatable aluminum-based aeronautical alloys containing various amounts of magnesium (Mg), iron (Fe), strontium (Sr) and beryllium (Be).;Tensile test bars (dendrite arm spacing ~ 24mum) were solutionized for either 5 or 12 hours at 540°C, followed by quenching in warm water (60°C). Subsequently, these quenched samples were aged at 160°C for times up to 12 hours. Microstructural assessment was performed. All heat-treated samples were pulled to fracture at room temperature using a servo-hydraulic tensile testing machine.;The results show that Be causes partial modification of the eutectic silicon (Si) particles similar to that reported for Mg addition. Addition of 0.8 wt.% Mg reduced the eutectic temperature by ~10°C. During solidification of alloys containing high levels of Fe and Mg, without Sr, a peak corresponding to the formation of a Be-Fe phase (Al8Fe2BeSi) was detected at 611°C. The Be-Fe phase precipitates in a script-like morphology.;A new quinary eutectic-like reaction was observed to take place near the end of solidification of high Mg, high Fe, Be-containing alloys. This new reaction is composed mainly of fine particles of Si, Mg2Si, pi-Al 8Mg3FeSi6 and (Be-Fe) phases. The volume fraction of this reaction decreased with the addition of Sr. The addition of Be has a noticeable effect on decreasing the beta-phase length, or volume fraction, this effect may be limited by adding Sr. Beryllium addition also results in the precipitation of the beta-phase in a nodular form, which reduces the harmful effects of these intermetallics on the alloy mechanical properties. Increasing both Mg and Fe levels led to an increase in the amount of the pi-phase; increasing the iron content led to an increase in the volume fraction of the partially soluble beta- and pi-phases, while Mg2Si particles were completely dissolved. The beta-phase platelets were observed to undergo changes in their morphology due to the dissolution, thinning, necking and fragmentation of these platelets upon increasing the solutionizing time. The pi-phase was observed to dissolve and/or transform into a cluster of very fine beta-phase platelets. In the as-cast conditions, increasing the Mg content leads to increased transformation of beta-phase platelets into Chinese-script pi-phase, regardless of the Fe content. This, in turn, decreases the harmful effect of the beta-phase.;Increasing the solutionizing time leads to a decomposition of the pi-phase to the beta-phase, fragmentation of the beta-phase and spheroidization of both the eutectic Si and the pi-phase particles, thus improving alloy tensile properties. Two mechanisms of Mg2Si precipitate coarsening were observed to occur: (1) Ostwald ripening in the solution heat-treated samples and (2) clustering. Coarsening increases with increased solution heat treatment time, increased aging time, as well as with greater Mg contents. Increased Fe levels decrease the alloy quality index (Q) values, whereas adding Mg increases them. Introducing Be, in spite of it being a toxic material, Sr, or both, simultaneously improves the alloy quality index values, regardless of solutionizing time or Fe and Mg levels.;Quality index values increase with solution heat treatment time from 5 to 12 hours. Higher Mg contents lead to an increase in alloy ductility, ultimate tensile strength (UTS) and yield strength (YS), while higher Fe levels can drastically decrease these properties. For the same levels of Fe and/or Mg, Be and Sr have significant effects in improving alloy mechanical properties; these effects can be readily observed in low levels of Fe and high Mg contents. Beryllium addition is beneficial in the case of high Fe contents as it lowers the harmful effects of Fe-phases in Al-Si alloys. In the case of high Fe contents, it seems that the addition of 500 ppm of Be is not sufficient for all interactions with other alloying elements. During the melting process the formation of Be-Sr phase (probably SrBe3O4 compound) decreases the free Be content and hence the alloy mechanical properties. The role of Be in preventing the oxidation of Mg and in changing the chemistry and morphology of the Fe-intermetallics is observed through improved mechanical properties of Be-containing alloys. The partial modification effect of both Mg and Be appears to improve the alloy tensile properties.;Solutionizing and aging times are important parameters affecting the alloy tensile properties. The Mg2Si precipitates were confirmed to be the main hardening components of the 356 and 357 alloys investigated. The yield strength increases with greater Mg levels, reduced Fe levels, addition of Be, Sr-modification, solution heat treatment time and aging time.;The present work was extended to include an investigation of the experimental 7073 aluminum alloy. (Abstract shortened by UMI.).