Evidence of disruption of Si-rich microstructure in engineering-lightweight Al-12.2at.%Si alloy melt above liquidus temperature

Sci Rep. 2020 Jul 31;10(1):12979. doi: 10.1038/s41598-020-69972-2.

Abstract

The exploration of microstructures in high temperature alloy melts is important for manufacturing of metallic components but extremely challenging. Here, we report experimental evidence of the disruption of Si-rich microstructure in engineering-lightweight Al-12.2at.%Si alloy melt at 1100 °C, via melt-spinning (MS) of Al1-xSix (x = 0.03,0.07,0.122,0.2) alloy melts from different initial melt temperatures, 800 °C and 1100 °C, under the super-high cooling rate of ~ 106 °C/s, in cooperation with the small angle neutron scattering (SANS) measurement. Si particles in 1100 °C MS alloys are abnormally smaller and increased in number at Al-12.2at.%Si, compared with 800 °C MS alloys, which demonstrates the disruption of Si-rich microstructure in Al-12.2at.%Si alloy melt at 1100 °C. SANS experiment verifies that large quantities of small (0-10 nm) Si-rich microstructures and small quantities of large (10-240 nm) Si-rich microstructures exist in Al-12.2at.%Si alloy melt, and the large Si-rich microstructures disrupt into small Si-rich microstructures with increasing of melt temperature from 800 to 1100 °C. Microstructure analysis of the MS alloys indicates that the large Si-rich microstructures in Al-12.2at.%Si alloy melt are probably aggregates comprising multiple small Si-rich microstructures. This work also provides a pathway for the exploration of microstructures in other high temperature alloy melts.