The present study was performed on A356 alloy [Al-7 wt %Si 0.0.35 wt %Mg]. To that La and Ce were added individually or combined up to 1.5 wt % each. The results show that these rare earth elements affect only the alloy melting temperature with no marked change in the temperature of Al-Si eutectic precipitation. Additionally, rare earth metals have no modification effect up to 1.5 wt %. In addition, La and Ce tend to react with Sr leading to modification degradation. In order to achieve noticeable modification of eutectic Si particles, the concentration of rare earth metals should exceed 1.5 wt %, which simultaneously results in the precipitation of a fairly large volume fraction of insoluble intermetallics. The precipitation of these complex intermetallics is expected to have a negative effect on the alloy performance.

In the present work, in-situ metal matrix composites were fabricated through squeeze casting. The copper particles were dispersed with different weight percentages (3%, 6%, 10%, and 15%) into Al-12% Si piston alloy. Also, heat treatments were performed at 380 °C and 450 °C for holding times of 6 and 18 h. The microstructures, X-ray diffractometer (XRD) pattern, hardness, and wear characteristics were evaluated. The results showed that these copper particles have reacted with the aluminum under all of the aforementioned processing conditions resulting in the formation of fine copper aluminide intermetallics. Most of the intermetallics were CuAl₂, while AlCu appeared in a small ratio. Additionally, these intermetallics were homogenously distributed within the alloy matrix with up to 6% Cu addition. The amounts of those intermetallics increased after performing heat treatment. Most of these intermetallics were CuAl₂ at 380 °C, while the Cu-rich intermetallics appeared at 450 °C. Increasing the holding time to 18 h, however, led to grain coarsening and resulted in the formation of some cracks. The hardness of the resulting composite materials was improved. The hardness value reached to about 170 HV after heat treating at 380 °C for 8 h. The wear resistance of the resulting composite materials was remarkably improved, especially at lower additions of Cu and at the lower heat treatment temperature.

Surface composite layers were successfully fabricated on an A 1050-H24 aluminum plate by dispersed iron (Fe) and magnetite (Fe₃O₄) particles through friction stir processing (FSP). Fe and Fe₃O₄ powders were packed into a groove of 3 mm in width and 1.5 mm in depth, cut on the aluminum plate, and covered with an aluminum sheet that was 2-mm thick. A friction stir processing (FSP) tool of square probe shape, rotated at a rate of 1000–2000 rpm, was plunged into the plate through the cover sheet and the groove, and moved along the groove at a travelling speed of 1.66 mm/s. Double and triple passes were applied. As a result, it is found that the Fe particles were homogenously distributed in the whole nugget zone at a rotation speed of 1000 rpm after triple FSP passes. Limited interfacial reactions occurred between the Fe particles and the aluminum matrix. On the other hand, the lower rotation speed (1000 rpm) was not enough to form a sound nugget when the dispersed particles were changed to the larger Fe₃O₄. The Fe₃O₄ particles were dispersed homogenously in a sound nugget zone when the rotation speed was increased to 1500 rpm. No reaction products could be detected between the Fe₃O₄ particles and the aluminum matrix. The saturation magnetization (Ms) of the Fe-dispersed nugget zone was higher than that of the Fe₃O₄-dispersed nugget zone. Moreover, there were good agreement between the obtained saturation magnetization values relative to that of pure Fe and Fe₃O₄ materials and the volume content of the dispersed particles in the nugget zone.

The present study was undertaken to evaluate the effect of temperature, immersion time, and different corrosive media such as HCl, H₂SO₄and KOH at different time intervals at 30 °C, 40 °C and 60 °C on the corrosion behavior of Fe and Ni-based alloy. The use of the design of experiment (DOE) and the analysis of variance (ANOVA) can be a useful methodology to reach this research. The analysis of the effects of each variable and their interaction on the corrosion of Fe and Ni-based alloys important role in selective best materials choice. The corrosion rate differs with different time intervals and different acid-base environments and increased with an increase in temperature from 30 to 60 °C. The study further reveals that the corrosion rate in different environment follows the order: HCl > H₂SO₄ > KOH.