A New Deformation-Semi-Solid Casting Process of Highly Concentrated Fe Containing Al-Si-Cu-Fe Cast Alloys

A newly proposed process of the deformation-semi-solid casting (D-SSC) process was applied to the highly concentrated Fe containing Al-7%Si-3%Cu-1%Fe alloys (in mass%) to eliminate the harmful influence of impurity Fe. The proposed D-SSC process consists of hot-deformation, heating to the semi-solid temperature and subsequent casting. The markedly improved microstructures and mechanical properties of the fabricated alloys by the D-SSC process were investigated. In the microstructure observation, the size and shape of the characteristic morphologies of the primary α-Al phase and the Fe containing intermetallic compound of the β-Al 5 FeSi phase were evaluated. the extremely refined β phase and the finely spheroidized α-Al phase are simultaneously achieved by the D-SSC process. The D-SSC process is found to be useful to modify the high amount of Fe into a harmless impurity.