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<p>Hypereutectic Al–Si alloys are limited in industrial applications because they contain coarse and angular primary silicon particles (PSPs). In this study, we employ a novel casting process, glass tube suction casting (GTSC), combined with solid-solution treatment to refine and spheroidize PSPs in a eutectic-divorced hypereutectic Al–Si alloy (A390) and increase its wear resistance. Following solid-solution treatment at 520&#xa0;°C for 4 hours, the average equivalent diameter (<i>D</i>) of the PSPs decreases from 18.8 to 5.2&#xa0;<i>μ</i>m, and the wear loss rate of mass decreases from 55.5 to 14.8 (mm<sup>3</sup>/(N&#xa0;m)) × 10<sup>−5</sup>). After being held for 6&#xa0;h, the spheroidization of the PSPs reached its optimal level, with the shape factor (reflecting the degree to which the irregular particles approached a spherical shape) increasing from the original value of 0.39 to 0.78. High-temperature in situ confocal tests revealed that, during solid-solution treatment, Si atoms tend to migrate from regions of higher surface curvature to those of lower curvature, passivating the sharp corners of the PSPs and achieving spheroidization and refinement through multifaced growth. The refinement and spheroidization of the PSPs, as well as the lattice distortion induced by the solid-solution treatment, contributed to an increase in the hardness of the matrix, thus providing favorable conditions for the increased wear resistance of the GTSC A390 alloy. The present study provides new insight into optimizing PSPs in hypereutectic Al–Si alloys for industrial applications.</p>

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Refinement and Spheroidization of Primary Silicon Particles in Eutectic-Divorced Hypereutectic Al–Si Alloy and Their Impact on Wear Resistance

  • 期刊论文

  • 发表日期：

    2025年7月17日

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  • Yuna Wu,
  • Chengcheng Han,
  • Zonghan Li,
  • Yitong Hu,
  • Chen Chen,
  • Jinghua Jiang,
  • Hengcheng Liao,
  • Yonghao Zhao

摘要

Hypereutectic Al–Si alloys are limited in industrial applications because they contain coarse and angular primary silicon particles (PSPs). In this study, we employ a novel casting process, glass tube suction casting (GTSC), combined with solid-solution treatment to refine and spheroidize PSPs in a eutectic-divorced hypereutectic Al–Si alloy (A390) and increase its wear resistance. Following solid-solution treatment at 520 °C for 4 hours, the average equivalent diameter (D) of the PSPs decreases from 18.8 to 5.2 μm, and the wear loss rate of mass decreases from 55.5 to 14.8 (mm3/(N m)) × 10−5). After being held for 6 h, the spheroidization of the PSPs reached its optimal level, with the shape factor (reflecting the degree to which the irregular particles approached a spherical shape) increasing from the original value of 0.39 to 0.78. High-temperature in situ confocal tests revealed that, during solid-solution treatment, Si atoms tend to migrate from regions of higher surface curvature to those of lower curvature, passivating the sharp corners of the PSPs and achieving spheroidization and refinement through multifaced growth. The refinement and spheroidization of the PSPs, as well as the lattice distortion induced by the solid-solution treatment, contributed to an increase in the hardness of the matrix, thus providing favorable conditions for the increased wear resistance of the GTSC A390 alloy. The present study provides new insight into optimizing PSPs in hypereutectic Al–Si alloys for industrial applications.