# Crystallisation and Microstructure of Sludge Particles in AlSi7Mg Secondary Alloys with Increased Iron Content

## TL;DR

This paper investigates how increased iron content affects the crystallisation and microstructure of sludge particles in recycled AlSi7Mg alloys, impacting their mechanical properties.

## Contribution

The study reveals how iron and manganese influence the formation and morphology of sludge particles in AlSi7Mg alloys during crystallisation.

## Key findings

- DSC analysis shows primary crystallisation of sludge particles and pre-eutectic α-Al15(Fe,Mn)3Si2 phase formation.
- The crystallisation temperature of sludge particles increases with the sludge factor (SF), from 620°C to 645°C.
- Higher iron and manganese content changes sludge particle morphology to compact, cluster-like structures.

## Abstract

The significant increase in the importance of silumin recycling in the context of sustainable development is driven by tangible ecological and economic benefits. However, the primary technological challenge associated with using scrap is the accumulation of iron, which promotes the formation of undesirable sludge particles, degrading the alloy’s mechanical properties. This paper presents a description of the phase transformations in an AlSi7Mg alloy with increased iron and manganese content. Analysis of data from Differential Scanning Calorimetry (DSC) revealed the primary crystallisation of sludge particles (SP) and the pre-eutectic precipitation of the α-Al15(Fe,Mn)3Si2 phase, which replaced the β-Al5FeSi phase. The remaining constituents of the AlSi7Mg alloy structure—α(Al) solid solution dendrites, the α(Al)+β(Si) eutectic, and the Mg2Si phase—crystallise regardless of the iron, manganese, and chromium content. It was established that the increase in the crystallisation temperature of SP, rich mainly in the elements mentioned above, is directly proportional to the increase in the value of the sludge factor (SF) and ranges from 620 °C (for SF~1.3%) to approx. 645 °C (for SF~3.1%). SEM studies revealed that the combined increase in iron and manganese content not only raises the precipitation temperature of SP but also alters its morphology from single polyhedra to compact, “cluster-like” structures. To avoid the presence of sludge particles in the AlSi7Mg alloy, which have an unfavourable morphology and reduce the yield of the melting process, the SF for high-pressure die-casting should not exceed 2.0%.