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 Ferich 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.