Shape, microstructure and wear of spray formed hypoeutectic Al–Si alloys

The manufacturing process through spray forming leads to give near-net-shape and fine grain microstructure. In this process Si particles, which are not distributed uniformly in conventional casting process, are distributed uniformly throughout the casting. In the present study disc shape spray form castings were made of Al–6.91Si and Al–10.1Si alloys, and then their shape, microstructure and wearing properties were studied. The shape of the deposit was observed to be the most uniform at 30° inclination angle of the substrate. Microstructure of spray formed alloys showed equiaxed grains morphology in contrast to as cast alloys. The wearing properties of Al–10.1Si alloy were found to be better than that of the Al–6.91Si alloy.