Three-Dimensional Network Structure and Mechanical Properties of Al-Cu-Ni-Fe Cast Alloys with Gd Micro-addition

High-temperature tensile testing and X-ray microscope (XRM) characterization were performed to assess the effects of the micro-addition of Gd and the three-dimensional (3-D) network structure on the improvement of Al-6Cu-3.5Ni-0.8Fe alloy under as-cast conditions. Gd addition contributed to the modification of the microstructure, where a new thermally stable micro-sized Al₃CuGd phase was formed, and the refinement occurred in Al₃CuNi and Al₉FeNi. The tensile test results revealed that the alloy modified with 0.4 pct Gd exhibited optimal properties at 623 K (350 °C), with an ultimate tensile strength, yield strength, and elongation of 74.1 MPa, 61.2 MPa, and 15.5 pct, respectively. Fractographic analysis after the tensile tests indicated that at ambient temperature, brittle cleavage-type fracture of the precipitates and ductile fracture of the matrix were dominant, whereas the transformation from mixed fracture to fully ductile trans-crystalline fracture was detected at elevated temperatures. According to the CT characterization, there was no significant difference in the curvature or interconnectivity of the 3-D network structure formed by the aluminides between before and after the tensile test at 623 K (350 °C). It is believed that the 3-D continuous network structure of aluminides, equipped with excellent heat resistance, plays a pivotal role in the high-temperature performance of the studied alloys. This work provides a new and promising idea for solving the current heat resistance problems of cast Al alloys.