The effects of cell spacing and distribution of intermetallic fibers on the mechanical properties of hypoeutectic Al–Fe alloys

The aim of the present investigation was to contribute to provide a basis for understanding how to control solidification parameters, microstructure and mechanical strength of Al–Fe alloys. Upward directional solidification experiments have been carried-out with commercially pure Al and Al–0.5 wt.% Fe, Al–1.0 wt.% Fe and Al–1.5 wt.% Fe alloys. The tensile tests results have been correlated to cell spacing (λ1), since cellular growth has prevailed along all obtained Al–Fe castings. The used casting assembly was designed in such way that the heat was extracted only through the water-cooled system at the bottom of the casting. In order to investigate the nature of Al–Fe intermetallic fibers, they were extracted from the aluminum-rich matrix by using a dissolution technique. These fibers were then investigated by SEM-EDAX microscopy. It was found that the ultimate tensile strength, yield tensile strength and elongation increase with decreasing cell spacing. The highest ultimate tensile strength was that obtained for the most refined microstructure, i.e. for the Al–1.5 wt.% Fe alloy sample, where a higher density of eutectic fibers was found distributed in a more homogeneous way along the casting section due to lower cell spacings. In contrast, the elongation was found to decrease with increasing solute content.