Improvement of deformation capacity of gas-atomized hypereutectic Al-Si alloy powder by annealing treatment

Gas-atomized pure metal or alloy powders are widely used as raw material in the preparation of high performance materials by powder metallurgy route (compaction and sintering). However, cold compactibility of gas-atomized Al-Si alloy powder is inhibited due to the high strength as a result of the refined Si phases and the supersaturated Al matrix. The effect of annealing on improving the compactibility of Al-Si alloy powder was studied. The densification was investigated by the HECKEL compaction equation in terms of deformation capacity. Moreover, the microstructures and bending fracture surfaces of the green compacts were examined to clarify the densification behavior. The results show that a maximum relative density of 96.1% is obtained when the powder is annealed at 400 degrees C. The deformation capacity is significantly improved by annealing treatment due to the softening of Al matrix, precipitation of supersaturated Si phases, dissolution of needle-like eutectic phase, and spheroidization of Si phases.