Tailoring Microstructure and Mechanical Properties of the Al-7Si-0.35Mg-0.35Fe Alloy by Cr Addition: A Study on Fe-Rich Phase Modification

Fe-rich phases are unavoidable intermetallic compounds in aluminum alloys, particularly in recycled aluminum. Their needle-like morphology not only impairs the mechanical performance of the alloy by disrupting the continuity of the matrix but also significantly reduces the allowable addition of recycled aluminum materials. Based on this, this study focuses on the Al-7Si-0.35Mg-0.35Fe alloy with a high Fe content. The Cr was introduced to modify the characteristics of the Fe-rich phase, and the microstructural evolution and mechanical properties of the aluminum alloy with different Cr content (0-0.25 wt.%) were investigated. Experimental results show that the secondary dendrite arm spacing of the alloy is significantly refined after Cr addition. Meanwhile, the Fe-rich phase gradually transitions from β-Al₅FeSi with needle-like morphology to α-Al₁₅(Fe,Cr)₃Si₂ with short rod-like or blocky morphology as the Cr content increases. Notably, the Fe-rich phase in the 0.20Cr alloy exhibits an approximately 65% increase in sphericity and an 84% reduction in equivalent diameter compared to those in the 0Cr alloy. The morphological blunting and dispersed distribution of Fe-rich phases lead to a broad effective Cr addition range of 0.05-0.20 wt% in the alloy. Among them, the 0.20Cr alloy exhibited the best comprehensive mechanical properties, with its ultimate tensile strength and elongation approximately 19% and 107% higher than those of the 0Cr alloy, respectively. Furthermore, the fracture morphology and the relationship between the Fe-rich phase and microcracks in Al-7Si-0.35Mg-0.35Fe alloys with different Cr contents were also analyzed.