Potential for improved mechanical properties in cast aluminium alloys

The aim of this work is to investigate the potential to improve the mechanical properties of some aluminium alloys, in order to obtain castings with optimum properties. Experiments have been made with pure aluminium, aluminium alloyed with 1% Si and 0,9% Mg and four aluminium cast alloys with 7-12% Si and various amounts of iron, magnesium, copper and manganese. To achieve the best possible solidification, gradient solidification technology of tensile specimen has been used, in order to explore the limits of the mechanical properties in relation to the microstructure. The experiments show that it is not possible to obtain good fracture toughness in alloys with a high iron content. The results also show that many of the aluminium alloys frequently used today are not processed in a way that allows optimal mechanical properties to be achieved. The alloys with a maximum of 0,4% Fe can give 10-23% fracture elongation, depending on other alloying elements such as Si, Mg and Cu. For these alloys it is worthwhile to improve the melt treatment and the casting process to obtain properties close to, or even better than can be achieved in other manufacturing processes. The experiments have given results for both columnar and equiaxed primary solidification structures