Microstructural features, wear, and corrosion behaviour of spray cast Al-Si alloys

Abstract

In the present study, the microstructural features, wear characteristics, and corrosion behaviour of spray cast Al-12Si, Al-15Si, and Al-20Si alloys have been investigated. The alloys were spray cast and hot isostatically pressed. Hot isostatic pressing has considerably reduced the porosity in spray cast alloys. The microstructure of spray cast alloys showed fine and globular-shaped Si particles in the Al matrix in contrast to needle-type eutectic Si and blocky-type primary Si in the Al matrix in chill cast alloys. The dry sliding wear tests showed that the wear rates of spray cast alloys are invariably lower and the potentiodynamic polarization tests showed that the corrosion resistance of spray cast alloys is considerably higher than that of chill cast alloys. The high wear and corrosion resistance of spray cast alloys have been discussed in the light of the microstructural modification induced during the spray casting process.