Characterization of Dendritic Microstructure, Intermetallic Phases, and Hardness of Directionally Solidified Al-Mg and Al-Mg-Si Alloys

Despite the widespread application of Al-Mg-Si alloys, especially in the automotive industry, interrelations of solidification thermal parameters (cooling rate and growth rate), microstructure, and hardness are not properly established. For instance, the control of the scale of the microstructure on both Al-Mg and Al-Mg-Si alloys by adequate pre-programming of the solidification thermal parameters remains a task to be accomplished. In the present study, the directional solidification (DS) of these alloys under unsteady-state solidification conditions is investigated in an attempt to characterize the evolution of microstructural features, macrosegregation, and hardness as a function of local solidification thermal parameters along the DS castings length. Silicon addition to the Al-Mg alloy was found not to affect the sizes of primary and secondary dendrite arm spacings, but induced the onset of tertiary dendritic branches and affected also the size and distribution of intermetallic particles within the interdendritic regions. The Al-Mg-Si alloy is characterized by a more complex arrangement of phases, including binary (α-Al + Mg₂Si) and refined ternary (α-Al + Mg₂Si + AlFe(Si) eutectic mixtures. As a consequence, a higher Vickers hardness profile is shown to be associated with the ternary Al-Mg-Si alloy DS casting. For both alloys examined, hardness is shown to increase with the increase in the microstructural spacing according to Hall–Petch type equations.