Iron is the most common and detrimental impurity in casting alloys and has been associated with many defects. The main consequence of the presence or adding of iron to AlSi alloys is the formation Fe-rich intermetallics with especially deleterious β-Al5FeSi. β-Al5FeSi phases are most often called needles on 2D micro sections, whilst platelets in 3D geometry. The x-ray tomography results have demonstrated Ferich phases with shapes different from simple forms such as needles or platelets and presented bent and branched phases. β grown as complicated structure of bent and branched intermetallics can decrease feeding ability, strengthen pores nucleation and eutectic colonies nucleation leading to lower permeability of mushy zone and porosity in the castings.
Directional solidification technique is an important research instrument to study solidification of metals and alloys. In the paper the model [6,7,8] of directional solidification in special Artemis-3 facility was presented. The current work aimed to propose the ease and efficient way in calibrating the facility. The introduced M coefficient allowed effective calibration and implementation of defined thermal conditions. The specimens of AlSi alloys with Fe-rich intermetallics and especially deleterious β-Al5FeSi were processed by controlled solidification velocity, temperature gradient and cooling rate.
Solidification of AlSiFe alloys was studied using a directional solidification facility and the CALPHAD technique was applied to calculate phase diagrams and to predict occurring phases. The specimens solidified by electromagnetic stirring showed segregation across, and the measured chemical compositions were transferred into phase diagrams. The ternary phase diagrams presented different solidification paths caused by segregation in each selected specimen. The property diagrams showed modification in the sequence and precipitation temperature of the phases. It is proposed in the study to use thermodynamic calculations with Thermo-Calc which enables us to visualize the mushy zone in directional solidification. 2D maps based on property diagrams show a mushy zone with a liquid channel in the AlSi7Fe1.0 specimen center, where significant mass fraction (33%) of β-Al5FeSi phases may precipitate before α-Al dendrites form. Otherwise liquid channel occurred almost empty of β in AlSi7Fe0.5 specimen and completely without β in AlSi9Fe0.2. The property diagrams revealed also possible formation of α–Al8Fe2Si phases.
The paper deals with the influence of manganese in AlSi7Mg0.3 alloy with higher iron content. Main aim is to eliminate harmful effect of intermetallic – iron based phases. Manganese in an alloy having an iron content of about 0.7 wt. % was graded at levels from 0.3 to 1.4 wt. %. In the paper, the effect of manganese is evaluated with respect to the resulting mechanical properties, also after the heat treatment (T6). Morphology of the excluded intermetallic phases and the character of the crystallisation of the alloy was also evaluated. From the obtained results it can be concluded that the increasing level of manganese in the alloy leads to an increase in the temperature of the β-Al5FeSi phase formation and therefore its elimination. Reducing the amount of β-Al5FeSi phase in the structure results in an improvement of the mechanical properties (observed at levels of 0.3 to 0.8 wt. % Mn). The highest addition of Mn (1.4 wt.%) leads to a decrease in the temperature corresponding to the formation of eutectic silicon, which has a positive influence on the structure, but at the same time the negative sludge particles were also present