Characterization of Rapidly Solidified Al-27 Si Hypereutectic Alloy: Effect of Solidification Condition

Rapidly solidified Al-27wt.% Si hypereutectic alloy was fabricated by gas atomization, and its characterization as a function of particle size was investigated. A relationship between the particle size and solidification condition was established to understand the microstructural characteristics. While the irregular primary Si phase transformed to quasi-spherical shape, and its size decreased gradually with the particle size, the primary Si morphology similar to that in ingot metallurgy sample was found from the deep-etched images. In the fine powder, the eutectic Si phase formed a network structure densely distributed in the matrix, while a tangled dendritic formed at the surface. From the distribution of the Si phase, it is suggested that the microstructure inhomogeneity increased as the particle size decreases. The structural distortion of the Al matrix was observed from x-ray diffraction patterns and differential scanning calorimetry curves. From the calculated results, an undercooling of 33 K (or interface velocity of 8 mm/s) was sufficient to suppress the primary Si to less than 2 mu m in the present composition. The microhardness increased significantly while the particle size decreases. The microstructure and properties of the bulk material consolidated by hot pressing of the powders obtained were also conducted.