Refinement of primary Si in hypereutectic Al-Si alloys by intensive melt shearing

Hypereutectic Al-Si based alloys are gaining popularity for applications where a combination of light weight and high wear resistance is required. The high wear resistance arising from the hard primary Si particles comes at the price of extremely poor machine tool life. To minimize machining problems while exploiting outstanding wear resistance, the primary Si particles must be controlled to a uniform small size and uniform spatial distribution. The current industrial means of refining primary Si chemically by the addition of phosphorous suffers from a number of problems. In the present paper an alternative, physical means of refining primary Si by intensive shearing of the melt prior to casting is investigated. Al-15wt% Si alloy has been solidified under varying casting conditions (cooling rate) and the resulting microstructures have been studied using microscopy and quantitative image analysis. Primary Si particles were finer, more compact in shape and more numerous with increasing cooling rate. Intensive melt shearing led to greater refinement and more enhanced nucleation of primary Si than was achieved by adding phosphorous. The mechanism of enhanced nucleation is discussed.