The effects of cooling rate 0.15, 1.5, 15, 150, and 1.5 × 105 °C/s on the microstructures and mechanical properties of Al-13Si-4Cu-1Mg-2Ni cast piston alloy were investigated. The results show that with an increase of solidification cooling rate, the secondary dendrite arm spacing (SDAS) of this model alloy can be calculated using the formula D = 47.126v − 1/3. The phases formed during the solidification with lower cooling rates primarily consist of eutectic silicon, M-Mg₂Si phase, γ-Al₇Cu₄Ni phase, δ-Al₃CuNi phase, ε-Al₃Ni phase, and Q-Al₅Cu₂Mg₈Si₆ phase. With the increase in the solidification cooling rate from 0.15 to 15 °C/s, the hardness increased from 80.9 to 125.7 HB, the room temperature tensile strength enhanced from 189.3 to 282.5 MPa, and the elongation at break increased from 1.6% to 2.8%. The ε -Al₃Ni phase disappears in the alloy and the Q phase emerges. The δ phase and the γ phase change from large-sized meshes and clusters to smaller meshes and Chinese script patterns. Further increase in the cooling rate leads to the micro hardness increasing gradually from 131.2 to 195.6 HV and the alloy solidifying into a uniform structure and forming nanocrystals.

In the present paper, the microstructures of three kinds of in-situ reinforcements Al-Ti-C, Al-Ti-B, and Al-Ti-B-C-Ce were deeply investigated using a combination of scanning electron microscopy, X-ray diffraction spectroscopy, and transmission electron microscopy. The effect of in-situ reinforcements on the room temperature and elevated temperature (350 °C) tensile strengths of Al-13Si-4Cu-1Mg-2Ni alloy were analyzed. It is found that doping with trace amounts of B and Ce, the size of the Al₃Ti phase in the in-situ reinforced alloy changed from 80 µm (un-reinforced) to about 10 µm, with the simultaneous formation of the AlTiCe phase. The Al-Ti-B-C-Ce reinforcement which is rapid solidified, was more effective and superior to enhance the tensile strengths of the Al-13Si-4Cu-1Mg-2Ni alloy, both at room and high temperatures than those of addition other reinforcements. The room temperature (RT) strength increased by 19.0%, and the 350 °C-strength increased by 18.4%.

The Al-Si-Cu-Mg-Ni alloy is a commonly used piston alloy. In this work, different amounts of phosphorus modifier and Al-2P (Al-2%P) master alloy modifier were added to the original alloy. The ultrasonic melt treatment method was also applied to improved the microstructure of near-eutectic multi-cast Al–Si alloys. Investigation was performed by means of optical microscopy and scanning electron microscopy. The results show that the effect of Al-2P master alloy modifier is more stable. However, the phosphorus modifier requires a higher amount of addition to achieve a refinement effect similar to that of the Al-2P modifier. The external ultrasonic field mainly acts on the AlP particle. The heterogeneous nucleation of the primary Si phase and the AlP clusters formed by the phosphorus modifier are more aggregated than the fine-dispersed AlP particles formed by the Al-2P master alloy modifier in the melt. Hence the ultrasonic melt treatment is more effective for the phosphorus modification.

The present study investigated microstructural evolution and changes in tensile properties of an Al-Si piston alloy subjected to thermal exposures at 250 and 350 °C for 150, 300, and 500 h. Microstructural and nanoscale precipitates were characterized using a combination of high-angle annular dark field-scanning transmission electron microscopy (HAADF-STEM) images and scanning electron microscopy (SEM). The tensile testing was performed. The results demonstrated that the thermal exposure induced granulation of the δ-Al₃CuNi particles, alongside precipitation of the θ-Al₂Cu phase particles and AlCu clusters within the matrix. Specifically, an increase in the size and number density of the θ-Al₂Cu phase particles was observed with exposure time at 250 °C. Conversely, at 350 °C, the θ-Al₂Cu particles exhibited a gradual increase in size with prolonged thermal exposure, coupled with a decrease in their number density. AlCu clusters precipitated solely at a thermal exposure temperature of 350 °C, with precipitation intensifying over time. Moreover, a decrease in the alloy’s tensile strength and an increase in elongation were noted after thermal exposure. Finally, the present study discussed the precipitation mechanisms of θ-Al₂Cu particles and AlCu clusters within the grains, suggesting that the AlCu clusters exerted a more effective strengthening effect compared to the θ-Al₂Cu particles.

Titanium alloys are considered one of the most promising materials. However, their poor thermal expansion property remains a major obstacle to their widespread application. In this study, we explored an innovative design strategy to tune the thermal expansion properties of titanium alloy. Specifically, we used rare earth iron intermetallic compounds (Gd-Fe IMCs) with low coefficient of thermal expansion (CTE) as expansion inhibitors to prepare composites with the required thermal expansion properties via in situ reaction. The morphology and size of Gd-Fe IMCs can be effectively controlled by electromagnetic and ultrasonic fields, resulting in a dense distribution of micro/nano-structured Gd-Fe IMCs and strong interfacial bonding of the composites. This alloy has an excellent CTE of 6.8 × 10⁻⁶/K and a high ultimate tensile strength of 921 MPa. The improvement in the physical properties (especially in thermal expansion properties) of titanium alloy can be attributed to the synergistic effect between Gd-Fe IMCs and Ti matrix. This design strategy can also be extended to other titanium alloys as a reference for designing low thermal expansion titanium alloys.