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Microstructural modification in an Al-Mg-Si (6082) alloy with high Fe content using inoculation and/or high-intensity ultrasonication

M.H. Khan, Amit Das Orcid Logo, T.I. Khan, Z. Li, H.R. Kotadia

Journal of Alloys and Compounds, Volume: 1012, Start page: 178500

Swansea University Author: Amit Das Orcid Logo

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DOI (Published version): 10.1016/j.jallcom.2025.178500

Abstract

In this study, the effects of solute Ti, chemical grain refiner (GR), and ultrasonication (UT) on the solidification behaviour and microstructure of a 6xxx (Al-1.0Mg-1.0Si) alloy with 1.0 wt% Fe impurity were examined. Primary-Al grains and eutectic Fe-intermetallic compounds (Fe-IMCs), predominantl...

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Published in: Journal of Alloys and Compounds
ISSN: 0925-8388
Published: Elsevier BV 2025
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URI: https://cronfa.swan.ac.uk/Record/cronfa68660
Abstract: In this study, the effects of solute Ti, chemical grain refiner (GR), and ultrasonication (UT) on the solidification behaviour and microstructure of a 6xxx (Al-1.0Mg-1.0Si) alloy with 1.0 wt% Fe impurity were examined. Primary-Al grains and eutectic Fe-intermetallic compounds (Fe-IMCs), predominantly α Al8Fe2Si/β Al9Fe2Si2, were identified as the major phases through thermodynamic prediction and microstructural observation. The results show that UT treatment produced the finest and most uniform microstructure, improving both grain refinement and Fe-IMC distribution, particularly compared to chemical methods. UT, when combined with GR, enhanced TiB2 dispersion and improved the nucleation of both Al grains and Fe-IMCs, leading to better refinement of the Fe-IMCs. Chemical inoculation also showed some effect, but UT consistently displayed finer, more uniform microstructures, and less aggregation of TiB2 particles. Although TiB2 particles appear to help nucleation of Fe-IMCs, refinement and distribution of the IMCs was primarily contributed by the size and distribution of intergranular liquid pockets, and consequently, the refinement of the Al-grain structure. Overall, the study highlights that UT, in combination with GR and TiB2, significantly improves the microstructure and controls Fe-IMC formation in high Fe 6xxx alloys, offering a promising approach for refining Al-Mg-Si alloys with high Fe content.
Keywords: Aluminium alloys; Iron containing intermetallics; Solidification; Ultrasonication; Cavitation; Inoculation; Microstructure refinement
College: Faculty of Science and Engineering
Funders: This research was funded by the Industrial Cooperative Awards in Science & Technology (CASE) (voucher no. 17000037). In addition to that, the characterisation facility is supported from the Higher Education Funding Council for England (HEFCE) fund and the WMG Centre for High Value Manufacturing Catapult is gratefully acknowledged.
Start Page: 178500

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