AL1914 Aluminum Silicon (Al-Si) Master Alloy
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Aluminum silicon alloy is a forged and cast alloy based on aluminum and silicon. AI-Si alloy is widely used in the automotive industry and machine manufacturing industry to produce parts for sliding friction conditions due to its light weight, good thermal conductivity and strength, hardness and corrosion resistance. When the silicon content is low (such as 0.7%), the aluminum-silicon alloy has good ductility and is commonly used as a deformed alloy. When the silicon content is high (such as 7%), the aluminum-silicon alloy melt has good filling properties.
A method of producing a silicon based alloy is described which comprises melting a silicon alloy containing greater than 50 wt.% silicon and preferably including aluminium. The melted alloy is then inert gas atomized to produce powder or a spray formed deposit in which the silicon forms a substantially continuous phase made up of fine, randomly oriented crystals in the microstructure. The alloy produced by the method has particularly useful application in electronics packaging materials and a typical example comprises an alloy of 70 wt.% silicon and 30 wt.% aluminium. Such an alloy is an engineering material which, for example, is machinable.
Aluminum-silicon alloys have become a popular choice for applications in the automotive and aerospace industries and have proven themselves through their fault-tolerant processability and respectable static properties at comparatively low costs. However, these alloys feature unique properties, when processed via laser powder bed fusion (LPBF). Although the finely dispersed silicon precipitates allow achieving fine-grained microstructures leading to superior static properties compared to those of their cast counterparts, they induce directional weak linkages through layered accumulation. This, in turn, reduces shear and crack tolerance and therefore weakens and strengthens the structure at the same point. Consequently, this necessitates a consideration of these effects when designing a part to be manufactured via LPBF. Heat treatments can be an addition to the processing routine and can enhance key properties, such as ductility and fatigue resistance, but generally reduce the static material strength. This chapter addresses these correspondences and sheds light on achievable properties across a wider range, including tensile, compressive, and torsional behaviors, fracture toughness, and fatigue resistance.
