Atomic-scale investigation into precipitated phase thickening in Al-Si-Mg-Cu alloy

Unified Interpretations of Two Kinds of Needle-Shaped Precipitates Using Transmission Electron Microscopy and Small-Angle Neutron Scattering in Aged Al-Mg2Si(-Cu) Alloys

This study investigates the nanostructural properties of pseudo-binary Al-1.0Mg2Si (mass%) alloys with and without 0.5Cu using transmission electron microscopy (TEM) and small-angle neutron scattering (SANS). The TEM results show that both alloys exhibit extra electron diffraction spots related to MgSiMg second clusters at peak-aged conditions. High-resolution TEM images have revealed that the second cluster exists as a needle-shaped precipitate that is shorter and thicker than the β″ phase. We found that the second cluster, which we referred to as the R phase in this paper, is more likely to form partially along the longitudinal axis of a random-type precipitate. Thus, the atomic arrangement in the random-type precipitate is not completely random. SANS is used to quantify the size and volume fraction of the observed needle-shaped precipitates since the R phase is difficult to observe with TEM. The R phase forms even in the Cu-free alloy, but the volume fraction is low, and the growth and formation are retarded near the peak-aged conditions. Undoubtedly, the Cu addition has the effect of stabilizing the growth of the R phase and also promoting its formation. Therefore, the R phase also contributes to the increase in hardness at both under- and peak-aged conditions in the Cu-containing alloy in addition to the strengthening β″ phases.

A First-Principles Study of the Cu-Containing β″ Precipitates in Al-Mg-Si-Cu Alloy

The nanostructured β″ precipitates are critical for the strength of Al-Mg-Si-(Cu) aluminum alloys. However, there are still controversial reports about the composition of Cu-containing β″ phases. In this work, first-principles calculations based on density functional theory were used to investigate the composition, mechanical properties, and electronic structure of Cu-containing β″ phases. The results predict that the Cu-containing β″ precipitates with a stoichiometry of Mg4+xAl2-xCuSi4 (x = 0, 1) are energetically favorable. As the concentration of Cu atoms increases, Cu-containing β″ phases with different compositions will appear, such as Mg4AlCu2Si4 and Mg4Cu3Si4. The replacement order of Cu atoms in β″ phases can be summarized as one Si3/Al site → two Si3/Al sites → two Si3/Al sites and one Mg1 site. The calculated elastic constants of the considered β″ phases suggest that they are all mechanically stable, and all β″ phases are ductile. When Cu atoms replace Al atoms at Si3/Al sites in β″ phases, the values of bulk modulus (B), shear modulus (G), and Young's modulus (E) all increase. The calculation of the phonon spectrum shows that Mg4+xAl2-xCuSi4 (x = 0, 1) are also dynamically stable. The electronic structure analysis shows that the bond between the Si atom and the Cu atom has a covalent like property. The incorporation of the Cu atom enhances the electron interaction between the Mg2 and the Si3 atom so that the Mg2 atom also joins the Si network, which may be one of the reasons why Cu atoms increase the structure stability of the β″ phases.

Morphological Evolutions of Ni-Rich Phases in Al-Si Piston Alloys during 250-400 °C Thermal Exposure Processes

The thermal stability of the Al-Si alloys during the thermal exposure process from 250 °C to 400 °C was systematically investigated. The relationships between the morphological evolution and the mechanical changes of the alloys were determined through the Vickers hardness test and materials characterization method. Initially, the alloys exhibited similar thermal degradation behavior. For example, the exposure process of the alloy at 300 °C can be divided into two stages according to the changes of the alloy hardness and the matrix micro-hardness. In detail, the first stage (0–2 h) exhibited a severe reduction of the alloy hardness while the second stage showed a more leveled hardness during the following 98 h. There are three identified morphological characteristics of Ni-rich phases in the alloy. Furthermore, the differences in both composition and the micro-hardness between these Ni-rich phases were confirmed. The underlying relationships between the morphological transformation of the Ni-rich phases and hardness fluctuation in the alloy were correlated and elucidated. The observed alloy hardness increase when the exposure temperature was 400 °C was unexpected. This behavior was explained from the perspectives of both Ni-rich phases evolution and dispersoid formation.