Microstructure and Tribological Property Correlations of Die Cast and Spray Formed Al-30 wt.% Si Alloy

Jump To References Section


  • SJC Institute of Technology, Chickballapur 562 101, Karnataka.
  • REVA University, Bengaluru 560 064, Karnataka.
  • REVA University, Bengaluru 560 064, Karnataka.
  • REVA University, Bengaluru 560 064, Karnataka.




Alloys, Mechanical properties, Microstructure, Wear properties.


Al-30 wt.% Si hypereutectic alloy was produced by die casting and spray forming technique. The microstructures, mechanical and tribological properties of the alloy were studied. The density of die cast and spray formed samples are measured using water displacement method by applying the Archimedes principle. The scanning electron micrographs of die cast and spray formed alloys revealed the morphological changes of silicon phase from coarse silicon needles to fine silicon needles due to high undercooling encountered in spray forming. The size of the hard silicon platelets are decreased from 22 µm to less than 10 µm as the processing method is changed from die casing to spray forming. The average Vickers micro hardness of die cast and spray formed alloy are 70.06±2.65 HV and 78.05±2.01 HV respectively. The respective yield strengths of die cast and spray formed alloy are 130±9MPa and 150 ±7 MPa and the compression strengths are 251±11.6 MPa and 283±6.32 MPa. The precipitation strengthening mechanism is found to be involved in spray formed alloy.



Ojha KV, Aruna Tomar, Devendra Singh and Kaushal GC (2008): Shape, microstructure and wear of spray formed hypoeutectic Al–Si alloys. Mater. Sci. and Eng. 487: 591- 596. DOI: https://doi.org/10.1016/j.msea.2007.10.032

Wang R, Lu W and Hogan LM (1999): Growth morphology of primary silicon in cast Al–Si alloys and the mechanism of concentric growth. J. Cryst. Grow. 207: 43-54. DOI: https://doi.org/10.1016/S0022-0248(99)00347-4

Sabatino MD and Arnberg L (2009): Castability of aluminum alloy. Trans. IIM62: 321-325. DOI: https://doi.org/10.1007/s12666-009-0049-2

Zeren M (2005): Effect of copper and silicon content on mechanical properties in Al-Cu-Si-Mg alloys. J. Mater. Pro. Tech. 69: 292-298. DOI: https://doi.org/10.1016/j.jmatprotec.2005.03.009

Roy P, Sarangi SK, Ghosh A and Chattopadhyay AK (2009): Machinability study of pure aluminum and Al-12 % Si alloys against uncoated and coated carbide inserts. Inter. J. Refra. Met. and Hard Mater. 27: 535-544. DOI: https://doi.org/10.1016/j.ijrmhm.2008.04.008

Qiyang L, Qingchun L and Qifu L (1991): Modification of Al-Si alloy with sodium. Act. Metal. et Mat. 39: 2497-2502. DOI: https://doi.org/10.1016/0956-7151(91)90064-8

Ojha SN, Jha JN and Singh SN (1991); Microstructural and modifications in Al-Si eutectic alloy processed by spray deposition. Scri. Metal. et Mat.25: 443-447. DOI: https://doi.org/10.1016/0956-716X(91)90208-I

Kim T, Lee B, Lee C R and Chun B (2001): Microstructure of rapidly solidified Al–20Si alloy powders. Mater. Sci. Engg.,A 304: 617-620. DOI: https://doi.org/10.1016/S0921-5093(00)01546-X

Srivastava VC, Mandal RK and Ojha SN (2001): Microstructure and mechanical properties of Al–Si alloys produced by spray forming process. Mater. Sci. Eng.A 304: 555-558. DOI: https://doi.org/10.1016/S0921-5093(00)01514-8

Fatahalla N, Hafiz M and Abdulkhalek M (1999): Effect of microstructure on the mechanical properties and fracture of commercial hypoeutectic Al-Si alloy modified with Na, Sb and Sr. J. Mater. Sci.34: 3555-3564. DOI: https://doi.org/10.1023/A:1004626425326




How to Cite

Mohan H. K, C., S, D., Swamy K. S, N., & B K, V. (2023). Microstructure and Tribological Property Correlations of Die Cast and Spray Formed Al-30 wt.% Si Alloy. Journal of Mines, Metals and Fuels, 70(10A), 307–313. https://doi.org/10.18311/jmmf/2022/32772