Enhanced grain refinement of Al-Si alloys by novel Al-V-B refiners

Abstract Al-V-B master alloy is promising for refining Al-Si alloys, yet its optimal composition with superior efficacy remains to be explored. In this work, the evolution of refining phases in the Al-10Si/Al-V-B system with different V:B ratios was evaluated by thermodynamic calculations, based on which the Al-V-B refiners with V:B = 1:1 and 5:1 were designed. Refining trails demonstrated that they could significantly reduce the grain size of Al-10Si (wt.%) alloy from 1736 to 184–245 μm with industrial addition amount. Detailed examinations results clarify that when V:B ratio is 1:1 the nucleation particle is (V,Al)B2, which has a VB2-AlB2 core-shell structure and therefore presents the nucleation capability as AlB2 particle. When V:B ratio is as high as 5:1, the nucleation particle is pure VB2. Density functional theory (DFT) calculation indicates that (0 0 0 1) VB2/(1 1 1) α-Al interface has the lowest interfacial energy such that highest nucleation potency among other types of diboride/α-Al interfaces under consideration. The outcomes of this work provide fundamental guidance to develop superior V-B based refiners for Al-Si alloys.