3D characterization of the fracture mechanisms of a Fe-rich Al-Si-Cu alloy

The effect of the defect size and morphology on the fatigue damage evolution was analysed in a recycled Al-Si-Cu alloy by micro-computed tomography and scanning electron microscopy. Fatigue tests were performed and the different crack initiation scenarios were characterized and classified. The interaction between shrinkage and gas pores was the key crack initiation mechanism and the ß-Al5FeSi particles did not play any role in the crack initiation phase. However, crack path analysis indicated that there is a certain amount of crack advance by brittle fracture of the β-phase particles. This is in accordance with the findings of tensile tests in which the ductility depended strongly on the iron content