Variations in Ductility and Microstructure in HPVDC AlSi10MnMg Alloy: Influence of Process-Induced Externally Solidified Crystals and Intermetallic Distribution
摘要
This study examines the role of microstructural heterogeneities in controlling tensile ductility in structural high-pressure vacuum die-cast (HPVDC) AlSi10MnMg (AuralTM-2) aluminum alloy. Two variants produced under similar processing conditions displayed markedly different ductility levels. Tensile specimens were extracted from multiple locations along the casting—from ingate to overflow—to evaluate spatial variations in mechanical properties. The typical (high-ductility) variant exhibited strong position-dependent elongation, increasing from ~8% near the ingate to up to 16% in central regions, reflecting the strong influence of local solidification conditions. In contrast, the lower ductility variant showed more uniform but consistently limited elongation (~6–8%) across all positions. Yield strength remained comparable between variants (~135 MPa), highlighting ductility as the more sensitive indicator of microstructural quality. Detailed microstructural analysis revealed that the high-ductility variant possessed a finer, more homogeneous microstructure, featuring lower fractions of coarse externally solidified crystals (ESCs), reduced sludge particles, and better-dispersed Fe-rich intermetallics compared to the lower ductility variant. Although the precise processing factors responsible for these differences could not be fully isolated, the results demonstrate a clear link between localized microstructural features and mechanical performance. These findings underscore the need for tight process control to minimize heterogeneities and optimize ductility in HPVDC structural components.