<p>The presence of excessive Fe content in recycled Al–Si–Cu alloys has persistently posed significant challenges for efficient material reuse. In this study, we propose an innovative magnetically controlled directional solidification technique. Our approach involves three critical steps: first, precisely control the precipitation location of the Al–Si–Fe phase through directional solidification; then, drive the directional migration of the precipitated Al–Si–Fe phases <i>via</i> magnetohydrodynamic vortex effect; last, sequential solidification of the purified melt to obtain the refined Al–Si–Cu alloy. This process successfully reduces the Fe content from 1&#xa0;wt&#xa0;pct ± 0.02&#xa0;wt&#xa0;pct to 0.38&#xa0;wt&#xa0;pct ± 0.06&#xa0;wt&#xa0;pct in the Fe-containing Al–Si–Cu alloy. Remarkable mechanical property enhancements are achieved, including: ultimate tensile strength increasing from 173.8 to 253.7&#xa0;MPa, uniform elongation rising from 1.2 to 5.3&#xa0;pct, and most notably, tensile toughness exhibiting a sixfold enhancement from 2.1 to 13.9&#xa0;MJ/m<sup>3</sup>.</p>

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Effect of Magnetically Controlled Directional Solidification on the Fe-Rich Phase Removal, Solidified Structure, and Mechanical Properties of Fe-Containing Al–Si–Cu Alloys

  • Zhe Shen,
  • Boyi Luo,
  • Dewei Xun,
  • Meng Sun,
  • Zhongze Lin,
  • Biao Ding,
  • Yunbo Zhong

摘要

The presence of excessive Fe content in recycled Al–Si–Cu alloys has persistently posed significant challenges for efficient material reuse. In this study, we propose an innovative magnetically controlled directional solidification technique. Our approach involves three critical steps: first, precisely control the precipitation location of the Al–Si–Fe phase through directional solidification; then, drive the directional migration of the precipitated Al–Si–Fe phases via magnetohydrodynamic vortex effect; last, sequential solidification of the purified melt to obtain the refined Al–Si–Cu alloy. This process successfully reduces the Fe content from 1 wt pct ± 0.02 wt pct to 0.38 wt pct ± 0.06 wt pct in the Fe-containing Al–Si–Cu alloy. Remarkable mechanical property enhancements are achieved, including: ultimate tensile strength increasing from 173.8 to 253.7 MPa, uniform elongation rising from 1.2 to 5.3 pct, and most notably, tensile toughness exhibiting a sixfold enhancement from 2.1 to 13.9 MJ/m3.