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<p>This study explores the impact of Semi-solid processing (SSP) on the microstructure, mechanical performance, and machinability of Al-7Si alloys, commonly used in aerospace due to their lightweight and high-strength properties. Conventional casting methods result in coarse dendritic structures, brittle behavior, and poor machinability, while SSP refines the microstructure, creating a globular <i>α</i>-Al matrix with uniformly distributed eutectic Si and Fe-intermetallics. Mechanical testing showed significant improvements, with tensile strength increasing from 55 to 115&#xa0;MPa, elongation rising from 2.1 to 9.3%, and compressive strength growing from 327 to 378&#xa0;MPa. Fractographic analysis indicated a shift from brittle to ductile fracture modes. X-ray CT scans revealed reduced porosity, and indentation tests highlighted phase-specific hardness variations. End-milling tests showed smoother surfaces and reduced roughness in SSP samples, though with higher cutting forces. Overall, SSP enhances both the structural integrity and machinability of Al-7Si alloys, offering a pathway for high-performance components in critical applications.</p>

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Experimental Investigation of Microstructure, Porosity and Machining Behavior of Cast and Semi-solid Processed Al–7Si Alloys

  • 期刊论文

  • 发表日期：

    2026年3月16日

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  • Gangarapu Akhila,
  • Srihari Dodla,
  • Sree Harsha Nandam

摘要

This study explores the impact of Semi-solid processing (SSP) on the microstructure, mechanical performance, and machinability of Al-7Si alloys, commonly used in aerospace due to their lightweight and high-strength properties. Conventional casting methods result in coarse dendritic structures, brittle behavior, and poor machinability, while SSP refines the microstructure, creating a globular α-Al matrix with uniformly distributed eutectic Si and Fe-intermetallics. Mechanical testing showed significant improvements, with tensile strength increasing from 55 to 115 MPa, elongation rising from 2.1 to 9.3%, and compressive strength growing from 327 to 378 MPa. Fractographic analysis indicated a shift from brittle to ductile fracture modes. X-ray CT scans revealed reduced porosity, and indentation tests highlighted phase-specific hardness variations. End-milling tests showed smoother surfaces and reduced roughness in SSP samples, though with higher cutting forces. Overall, SSP enhances both the structural integrity and machinability of Al-7Si alloys, offering a pathway for high-performance components in critical applications.