Effect of silicon content in grain refining hypoeutectic Al–Si foundry alloys with boron and titanium additions

The effect of Si content on the grain refinement of hypoeutectic Al–Si alloys was investigated. Alloying with Si refines the grain structure, which tends to be coarse and columnar in commercially pure aluminium. The smallest grain size occurs at ∼2 wt-%Si, where the solidification interval of hypoeutectic Al–Si alloys is the largest. Grains become increasingly coarser with increasing Si starting from this point. The grains of Al–Si alloys with 500 ppm Ti are smaller than those cast without Ti regardless of the Si content of the alloy. The fivefold reduction in grain size in commercially pure aluminium upon Ti addition is gradually reduced with increasing Si. Finally, the grain refinement provided by Ti fails to meet the expectations once Ti starts to be removed from the melt via the formation of Ti–Si compounds above 5 wt-%Si. The B addition relies on the formation of AlB2 particles to offer grain refinement. Analysis of the Al rich corner of the calculated Al–Si–B liquidus surface suggests that the primary AlB2 is formed at a Si concentration of ∼4 wt-%. While a perfect grain refiner for hypoeutectic Al–Si alloys with at least 4 wt-%Si, B fails to refine the grain structure when the Si content is less.