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<p>Mechanical vibration during solidification offers a physical route for tailoring the microstructure and mechanical properties of aluminum–silicon alloys without altering chemical composition. In this study, an Al–12 wt.% Si alloy was subjected to low-frequency, sign-alternating vibration (20–180 Hz) with controlled duty cycles (30–90 %) using a custom-built electromagnetic platform. Microstructural analysis revealed that vibration promotes refinement of dendritic α-Al and non-metallic inclusions, with duty cycle exerting a more pronounced influence than vibration frequency. Optimal conditions (90–180 Hz, 50 % duty cycle) increased ultimate tensile strength by up to 2.5 times relative to as-cast material, while correlations between tensile strength and inclusion density, size, and dendritic branch density emphasized the critical role of microstructural distribution. Numerical modeling of thermal and solute transport supports the experimental findings, showing that intermediate duty cycles reduce thermal and concentration heterogeneity and smooth solidification kinetics. Subsequent hot deformation further enhanced mechanical performance, demonstrating the persistence of vibration-induced microstructural features. The results indicate that mechanical vibration, particularly with optimized duty cycle and frequency, is a robust tool for microstructure control in Al–Si alloys, providing a scalable and compositionally neutral alternative to conventional chemical modifiers.</p>

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Vibration-Assisted Solidification: Duty Cycle and Frequency Effects on a hypoeutectic Al–12 wt.% Si Alloy Microstructure and Strength

  • 期刊论文

  • 发表日期：

    2026年5月22日

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  • Vladislav Kaverinskiy,
  • Zoya Sukhenko,
  • Dmytro Verbylo,
  • Gennadii Bagliuk

摘要

Mechanical vibration during solidification offers a physical route for tailoring the microstructure and mechanical properties of aluminum–silicon alloys without altering chemical composition. In this study, an Al–12 wt.% Si alloy was subjected to low-frequency, sign-alternating vibration (20–180 Hz) with controlled duty cycles (30–90 %) using a custom-built electromagnetic platform. Microstructural analysis revealed that vibration promotes refinement of dendritic α-Al and non-metallic inclusions, with duty cycle exerting a more pronounced influence than vibration frequency. Optimal conditions (90–180 Hz, 50 % duty cycle) increased ultimate tensile strength by up to 2.5 times relative to as-cast material, while correlations between tensile strength and inclusion density, size, and dendritic branch density emphasized the critical role of microstructural distribution. Numerical modeling of thermal and solute transport supports the experimental findings, showing that intermediate duty cycles reduce thermal and concentration heterogeneity and smooth solidification kinetics. Subsequent hot deformation further enhanced mechanical performance, demonstrating the persistence of vibration-induced microstructural features. The results indicate that mechanical vibration, particularly with optimized duty cycle and frequency, is a robust tool for microstructure control in Al–Si alloys, providing a scalable and compositionally neutral alternative to conventional chemical modifiers.