Effect of Casting Process and Thermal Exposure on Microstructure and Mechanical Properties of Al-Si-Cu-Ni Alloy

This paper employed squeeze-casting (SC) technology to develop a novel Al-7Si-1.5Cu-1.2Ni-0.4Mg-0.3Mn-0.15Ti heat-resistant alloy, addressing the issue of low room/high temperature elongation in traditional gravity casting (GC). Initially, the effects of SC and GC processes on the microstructure and properties of the alloy were investigated, followed by an examination of the evolution of the microstructure and properties of the SC samples over thermal exposure time. The results indicate that the SC process significantly improves the alloy’s microstructure. Compared to the GC alloy, the secondary dendrite arm spacing of the as-cast SC alloy is refined from 50.5 μm to 18.5 μm. Meanwhile, the size and roundness of the eutectic Si phase in the T6-treated SC alloy are optimized from 11.7 μm and 0.75 μm to 9.5 μm and 0.85 μm, respectively, and casting defects such as porosity are reduced. Consequently, the ultimate tensile strengths (UTSs) at room temperature and at 250 °C of the SC alloy are 5% and 4.9% higher than that of GC alloy, respectively, and its elongation at both temperatures shows significant improvement. After thermal exposure at 250 °C for 120 h, the morphology of the residual second phase at the grain boundaries in the SC alloy becomes more rounded, but the eutectic Si and nano-precipitates undergo significant coarsening, resulting in a 49% decrease in UTS.