Chemical leaching of rapidly solidified Al-Si binary alloys

Various particulate precursors of Al100-xSix (x = 5-12) alloys were prepared by a rapid solidification process. The rapidly solidified structures of the precursors were examined by XRD, DSC and SEM. Most of Si atoms were dissolved into the alpha-Al(fcc) phase by rapid solidification though the solubility of Si in the alpha-Al phase is negligibly small in conventional solidification. In the case of 5 at.% Si alloy, a single alpha-Al phase was only formed. The amount of the primary Si phase increased with increase of Si content for the alloys beyond 8 at.% Si. Rapid solidification was effective to form super-saturated alpha-Al precursors. These precursors were chemically leached by using a basic solution (NaOH) or a hydrochloric acid (HCl) solution. All Al atoms were removed by a HCl solution as well as a NaOH solution. Granules of the Si phase were newly formed during leaching. The specific surface area was about 50-70 m(2)/g independent of Si content. The leaching behavior in both solutions was slightly different. In the case of a NaOH solution, the shape of the precursor often degenerated after leaching. On the other hand, it was retained after leaching by a HCl solution. Fine Si particles precipitated in the alpha-Al phase by annealing of as-rapidly solidified precursors at 773 K for 7.2 x 10(3) s. In this case, it was difficult to obtain any products by NaOH leaching, but a few of Si particles were obtained by HCl leaching. Precipitated Si particles were dissolved by the NaOH solution. The X-ray diffraction patterns of leached specimens showed broad lines of the Si phase and its lattice constant was slightly larger than that of the pure Si phase. The microstructures of the leached specimens were examined by transmission electron microscopy. It showed that the leached specimens had a skeletal structure composed of slightly elongated particles of the Si phase and quite tine pores. The particle size was about 30-50 nm. It was of comparable order with that evaluated by Scherer's equation. Leaching of rapidly solidified precursors was effective to form skeletal structures composed of fine Si particles with pores. (c) 2005 Elsevier B.V. All rights reserved.