Effect of Complex Alloying on the Phase Composition and Thermal Characteristics of Al–Fe–Si Aluminum Alloys

Authors

  • V.A. Andreyachshenko Abylkas Saginov Karaganda Technical University

DOI:

https://doi.org/10.31643/2027/6445.12

Keywords:

Al-Fe-Si, ThermoCalc software, intermetallic phases, phase equilibrium, synergistic alloying.

Abstract

This study presents a comprehensive analysis of phase formation in Al–Fe–Si aluminum alloys with the addition of ten industrially significant alloying elements (Mg, Cu, Ni, Mn, Cr, Zn, Ti, Zr, V, Be), performed using thermodynamic modeling via the Thermo-Calc software package. Phase formation was investigated and compared in a commercial alloy (Al98–Fe1–Si1) and an intermetallic alloy (Al60–Fe33–Si7) under both individual and synergistic alloying conditions. The thermal characteristics (liquidus, solidus, and α- and β-transformations) and phase constituents were analyzed across a broad temperature range (0–1200 °C). It was found that the alloying elements exert diverse effects on phase stability and alloy structure, with intermetallic systems exhibiting greater thermal stability. Particular attention was given to the formation of the matrix phase and the influence of synergistic alloying on phase equilibria and the potential emergence of new stable compounds. The results provide a basis for targeted alloy design, including the use of secondary aluminum, to develop materials with tailored properties for transportation and mechanical engineering applications.

Downloads

Download data is not yet available.

Author Biography

V.A. Andreyachshenko, Abylkas Saginov Karaganda Technical University

PhD, associate professor, Head of the Testing Laboratory Engineering Profile Comprehensive Development of Mineral Resources, Abylkas Saginov Karaganda Technical University, N. Nazarbayev Ave., 56, Karaganda, Kazakhstan. ORCID ID: https://orcid.org/0000-0001-6933-8163

References

Padalko AG, Pyrov MS, Karelin RD, Yusupov VS, Talanova GV. Barothermal Treatment, Cold Plastic Deformation, Microstructure and Properties of Binary Silumin Al–8 at % Si. Russ. Metall. 2021, 1155–1164. https://doi.org/10.1134/S0036029521090123

Becker H, Thum A, Distl B, Kriegel MJ, Leineweber A. Effect of melt conditioning on removal of Fe from secondary Al-Si alloys containing Mg, Mn, and Cr. Metallurgical and Materials Transactions A. 2018; 49:6375-6389. https://doi.org/10.1007/s11661-018-4930-7

Arbeiter J, Vončina M, Volšak D, Medved J. Evolution of Fe-based intermetallic phases during homogenization of Al–Fe hypoeutectic alloy. Journal of Thermal Analysis and Calorimetry. 2020; 142(5):1693-1699. https://doi.org/10.1007/s10973-020-10161-8

Lee JY, Heo H, Kang N, Kang CY. Microstructural Evolution of Reaction Layer of 1.5 GPa Boron Steel Hot-Dipped in Al-7wt% Ni-6wt% Si Alloy. Metals. 2018; 8(12):1069. https://doi.org/10.3390/met8121069

Khan MH, Das A, Li Z, Kotadia HR. Effects of Fe, Mn, chemical grain refinement and cooling rate on the evolution of Fe intermetallics in a model 6082 Al-alloy. Intermetallics. 2021; 132:107132. https://doi.org/10.1016/j.intermet.2021.107132

Kocich R, Kunčická L. Optimizing Structure and Properties of Al/Cu Laminated Conductors via Severe Shear Strain. J. Alloys Compd. 2023; 953:170124. https://doi.org/10.1016/j.jallcom.2023.170124

Wang C, Yu F, Zhao D, Zhao X, Zuo L. Microstructure Evolution of Al-15% Si Alloy during Hot Rolling. Philos. Mag. Lett. 2018; 98:456–463. https://doi.org/10.1080/09500839.2019.1573332

Cepeda-Jiménez CM, García-Infanta JM, Zhilyaev AP, Ruano OA, Carreño F. Influence of the Supersaturated Silicon Solid Solution Concentration on the Effectiveness of Severe Plastic Deformation Processing in Al–7wt.% Si Casting Alloy. Mater. Sci. Eng. A. 2011; 528:7938–7947. https://doi.org/10.1016/j.msea.2011.07.016

Andreyachshenko VA. Finite element simulation (FES) of the fullering in device with movable elements. Metalurgija. 2016; 55(4):829-831.

Naizabekov AB, Andreyachshenko VA, Kliber J, Kocich R. Tool for realization several plastic deformation. In: 22th International Conference on Metallurgy and Materials METAL; Brno, Czech Republic. 2013, 317-321.

Belov NA, Alabin AN, Matveeva IA, Eskin DG. Effect of Zr additions and annealing temperature on electrical conductivity and hardness of hot rolled Al sheets. Trans. Nonferrous Met. Soc. China. 2015; 25:2817-2826. https://doi.org/10.1016/S1003-6326(15)63907-3

Jiang H, Li S, Zhang L, He J, Zheng Q, Song Y, et al. The influence of rare earth element lanthanum on the microstructures and properties of as-cast 8176 (Al-0.5 Fe) aluminum alloy. Journal of Alloys and Compounds. 2021; 859:157804. https://doi.org/10.1016/j.jallcom.2020.157804

Chen Y, Xiao C, Zhu S, Li Z, Yang W, Zhao F, et al. Microstructure characterization and mechanical properties of crack-free Al-Cu-Mg-Y alloy fabricated by laser powder bed fusion. Additive Manufacturing. 2022; 58:103006. https://doi.org/10.1016/j.addma.2022.103006

Zhu H, Li J. Advancements in corrosion protection for aerospace aluminum alloys through surface treatment. International Journal of Electrochemical Science. 2024; 19(2):100487. https://doi.org/10.1016/j.ijoes.2024.100487

Fan T, Ruan Z, Zhong F, Xie C, Li X, Chen D, et al. Nucleation and growth of L12-Al3RE particles in aluminum alloys: A first-principles study. Journal of Rare Earths. 2023; 41(7):1116-1126. https://doi.org/10.1016/j.jre.2022.05.018

Wang T, Chen C, Ma J, Wei S, Xiong M, et al. Influence of Si on the intermetallic compound formation in the hot-dipped aluminide medium carbon steel. Materials Characterization. 2023; 197:112700. https://doi.org/10.1016/j.matchar.2023.112700

Sersour Z, Amirouche L. Effect of Alloying Additions and High Temperature T5-Treatment on the Microstructural Behavior of Al–Si-Based Eutectic and Hypo-Eutectic Alloys. Int. J. Met. 2022; 16:1276–1291. https://doi.org/10.1007/s40962-021-00676-7

Alemdag Y, Karabiyik S, Mikhaylovskaya AV. Kishchik, M.S.; Purcek, G. Effect of Multi-Directional Hot Forging Process on the Microstructure and Mechanical Properties of Al–Si Based Alloy Containing High Amount of Zn and Cu. Mater. Sci. Eng. A. 2021; 803:140709. https://doi.org/10.1016/j.msea.2020.140709

Tsaknopoulos K, Walde C, Tsaknopoulos D, Cote DL. Evolution of Fe-Rich Phases in Thermally Processed Aluminum 6061 Powders for AM Applications. Materials. 2022; 15(17):5853. https://doi.org/10.3390/ma15175853

Zhang X, Wang D, Li X, Zhang H, Nagaumi H. Understanding crystal structure and morphology evolution of Fe, Mn, Cr-containing phases in Al-Si cast alloy. Intermetallics. 2021; 131:107103. https://doi.org/10.1016/j.intermet.2021.107103

Fang CM, Que ZP, Fan Z. Crystal chemistry and electronic structure of the β-AlFeSi phase from first-principles. Journal of Solid State Chemistry. 2021; 299:122199. https://doi.org/10.1016/j.jssc.2021.122199

Que Z, Fang C, Mendis CL, Wang Y, Fan Z. Effects of Si solution in θ-Al13Fe4 on phase transformation between Fe-containing intermetallic compounds in Al alloys. Journal of Alloys and Compounds. 2023; 932:167587. https://doi.org/10.1016/j.jallcom.2022.167587

Wang M, Guo Y, Wang H, Zhao S. Characterization of Refining the Morphology of Al–Fe–Si in A380 Aluminum Alloy Due to Ca Addition. Processes. 2022; 10(4):672. https://doi.org/10.3390/pr10040672

Xia X, Chen M, Lu Y-J, Fan F, Zhu C, Huang J, Deng T, Zhu S. Microstructure and Mechanical Properties of Isothermal Multi-Axial Forging Formed AZ61 Mg Alloy. Trans. Nonferrous Met. Soc. China. 2013; 23:3186–3192. https://doi.org/10.1016/S1003-6326(13)62851-4

Kocich R. Effects of Twist Channel Angular Pressing on Structure and Properties of Bimetallic Al/Cu Clad Composites. Mater. Des. 2020; 196:109255. https://doi.org/10.1016/j.matdes.2020.109255

Asadikiya M, Yang S, Zhang Y, Lemay C, Apelian D, Zhong Y. A Review of the Design of High-Entropy Aluminum Alloys: A Pathway for Novel Al Alloys. J. Mater. Sci. 2021. 56: 12093–12110. https://doi.org/10.1007/s10853-021-06042-6

Aranda VA, Figueroa IA, González G, García-Hinojosa JA, Alfonso I. Study of the microstructure and mechanical properties of Al-Si-Fe with additions of chromium by suction casting. Journal of Alloys and Compounds. 2021; 853:157155. https://doi.org/10.1016/j.jallcom.2020.157155

Pang N, Shi Z, Wang C, Li N, Lin Y. Influence of Cr, Mn, Co and Ni Addition on Crystallization Behavior of Al13Fe4 Phase in Al-5Fe Alloys Based on ThermoDynamic Calculations. Materials. 2021; 14(4):768. https://doi.org/10.3390/ma14040768

Hemachandra M, Mamedipaka R, Kumar A, Thapliyal S. Investigating the Microstructure and Mechanical Behavior of Optimized Eutectic Al Si Alloy Developed by Direct Energy Deposition. J. Manuf. Process. 2024; 110:398–411. https://doi.org/10.1016/j.jmapro.2024.01.002

Cheng W, Liu CY, Ge ZJ. Optimizing the Mechanical Properties of Al–Si Alloys through Friction Stir Processing and Rolling. Mater. Sci. Eng. A. 2021; 804:140786. https://doi.org/10.1016/j.msea.2021.140786

Downloads

Published

2025-10-03

How to Cite

Andreyachshenko, V. (2025). Effect of Complex Alloying on the Phase Composition and Thermal Characteristics of Al–Fe–Si Aluminum Alloys. Kompleksnoe Ispolzovanie Mineralnogo Syra = Complex Use of Mineral Resources, 340(1), 117–126. https://doi.org/10.31643/2027/6445.12