Spray forming of hypereutectic Al–Si alloys

To develop advanced aluminum alloys with high silicon content, hypereutectic aluminum silicon alloys AlSix (x = 18, 25, and 35 wt.%) in the form of cylindrical billet have been spray formed under different thermal conditions. To help in spray forming parameter selection and interpretation of experimental results, phase diagram of the alloys and their thermochemical data such as liquid fractions and enthalpies in function of temperature have been calculated. The spray formed hypereutectic Al–Si alloys are typically composed of refined and uniformly distributed primary silicon and modified eutectic. Thermal conditions and silicon content of the deposited materials have significant influence on the metallurgical quality of the spray formed Al–Si alloys. Strong cooling condition is required for spray forming Al–Si alloys with high silicon content.