Effect of solidification pressure on the corrosion behavior and mechanical properties of Al-7Si-3Cu-(0.4 Mg)-(0.5Ge) alloys

Developing practical microstructural solutions that simultaneously enable excellent corrosion resistance and mechanical properties in Al-Si-Cu-based alloys has been increasingly in demand. In this study, we attempt to tailor the microstructural evolution to manipulate the mechanical performance and corrosion resistance of Al-7Si-3Cu-(0.4 Mg)-(0.5Ge) alloys fabricated by GPa-level pressure combined with solution and/or aging treatments. It was found that as the solidification pressure increased, the dendritic growth tendency of the α-Al phase became less pronounced, and the modification of eutectic Si became increasingly significant. Complete solid solution alloys were even achieved under 6 GPa. The corresponding kinetic and thermodynamic mechanisms of pressure-induced microstructural evolution were explored in detail. Upon aging treatment, dense irregular Si precipitates emerged from the supersaturated matrix in Al-7Si-3Cu alloys solidified at 5 GPa and 6 GPa, while denser and finer Si precipitates growing along the 〈1 0 0〉_Al directions dominated the matrix of Al-7Si-3Cu-0.4 Mg-0.5Ge alloys, which resulted in considerable enhancement of mechanical properties. The electrochemical corrosion behavior was evaluated in the as-cast and heat-treated conditions. The underlying corrosion mechanisms were discussed in terms of pressure, supersaturated solutes and precipitates. These results reveal the feasibility of designing high-strength and corrosion-resistant Al-Si-Cu series alloys via the manipulation of pressure and heat treatment.