Microstructure, mechanical properties and wear behaviour of Al-20Si-3Fe alloy prepared by spray conform

Spray Conform (SC) is an innovative technique, which combines the spray forming and Conform extrusion processes. In this paper, Al–20Si–3Fe alloy has been prepared by this technique. The typical microstructure, mechanical property and wear behaviour of the alloy were investigated. Results show that both Si particles and intermetallics in the alloy were greatly refined with a size of less than 5 μm, and these intermetallics were well aligned in the extrusion direction. Compared with cast alloy, both the mechanical property and wear resistance of the SC alloy have been greatly improved. In particular, the ultimate tensile strength of the alloy is three times more than its conventionally cast counterpart. What's more, high sliding temperature results in a high wear rate but a low frictional coefficient. Wear micromechanics of the SC alloy is abrasive wear and delamination wear at room temperature, and plastic deformation and delamination wear at 200 °C.