Effect of High-Frequency Electric Pulse on the Solidification Microstructure and Properties of Hypoeutectic Al-Si Alloy

The effects of different pulse frequencies on the microstructure grain size and solid solubility of Al-9Si alloy were systematically investigated using OM, SEM, and EDS. The impact on the mechanical properties of the alloy was analyzed using a micro-Vickers hardness tester and multifunctional friction tester. During solidification, the Al-9Si alloy is exposed to high-frequency electric current pulses with a current density of 300 A/cm2 and frequencies of 0 Hz, 500 Hz, 1000 Hz, and 2000 Hz. The experimental results show that the Lorentz force also increases as the high-frequency pulse frequency increases. Intense electromagnetic stirring leads to grain refinement. However, as the pulse frequency continues to grow, the combined effect of Joule heating and Lorentz force results in an enlargement of the melt zone and an increase in grain size. At a pulse frequency of 1000 Hz, the eutectic structure size of the Al-9Si alloy is optimal, with the average size being reduced to 13.87 mu m and a dense distribution, effectively eliminating primary Si. The EDS results revealed that the high-frequency pulse led to a more uniform distribution of Si elements within the matrix, and the solid solubility of Si in the alpha-Al matrix increased to a maximum value of 1.99%, representing a 39.2% increase. At a pulse frequency of 1000 Hz, the sample demonstrates the most favorable mechanical properties, with the friction coefficient reaching a minimum value of 0.302, representing a 37.7% decrease in the average friction coefficient. The results demonstrate that high-frequency pulsing is an effective method for enhancing the mechanical properties of Al-9Si alloy.