Effect of periodic melt shearing process and cooling rate on structure and hardness of Al–0.7Fe aluminum alloy

• Melt shearing process refines the grain size and SDAS of Al–Fe alloy.
• Increasing cooling rate refines the grain size and SDAS of Al–Fe alloy.
• Melt shearing process improves the Al3Fe and Al6Fe intermetallic particles.
• The hardness decreases with increasing cooling rate and times of melt shearing.

In this investigation, the effect of periodic melt shearing process and cooling rate on an Al–Fe alloy was studied. Microstructural examinations were conducted by X-ray diffraction, optical and scanning electron microscopy coupled with energy dispersive spectrometry (EDS). Experimental results suggest that shearing above melting point can refine the alloy structure and improve the morphology of intermetallic phases and; the level of refinement is increased by increase of shearing time. Also, increasing cooling rate through reduced sections, decreases grain size and secondary dendrite arm spacing (SDAS) and improves the microstructure of Al–Fe alloy. The results of hardness test showed that increasing cooling rate and time of melt shearing reduce the hardness of Al–Fe alloy.