The present thesis investigates the grain refinement in solidifying Al-7wt%Si hypoeutectic alloy driven by electric currents. The grain size reduction in alloys generated by electric currents during the solidification has been intensively investigated. However, since various effects of electric currents have the potential to generate the finer equiaxed grains, it is still argued which effect plays the key role in the grain refinement process. In addition, the knowledge about the grain refinement mechanism under the application of electric currents remains fragmentary and inconsistent. Hence, the research objectives of the present thesis focus on the role of electric current effects and the grain refinement mechanism under the application of electric currents. Chapter 1 presents an introduction with respect to the subject of grain refinement in alloys driven by electric current during the solidification process in particular, including the research objectives; the research motivation; a brief review about the research history; a short introduction on the electric currents effects and a review relevant to the research status of grain refinement mechanism. Chapter 2 gives a description of research methods. This chapter shows the employed experiment materials, experimental setup, experimental procedure, the analysis methods of solidified samples, and numerical method, respectively. Chapter 3 focuses on the role of electric current effects in the grain refinement process. A series of solidification experiments are performed under various values of effective electric currents for both, electric current pulse and direct current. The corresponding temperature measurements and flow measurements are carried out with the increase of effective electric current intensity. Meanwhile, numerical simulations are conducted to present the details of the flow structure and the distribution of electric current density and electromagnetic force. Finally, the role of electric current effects is discussed to find the key effect in the grain refinement driven by electric currents. Chapter 4 investigates the grain refinement mechanism driven by electric currents. This chapter mainly focuses on the origin of finer equiaxed grain for grain refinement under the application of electric current on account of the importance of the origin for understanding the grain refinement mechanism. A series of solidification experiments are carried out in Al-7wt%Si alloy and in high purity aluminum. The main origin of equiaxed grain for grain refinement is concluded based on the experiment results. Chapter 5 presents three further investigations based on the achieved knowledge in chapter 3 and 4 about the role of electric current effects and the grain refinement mechanism. According to the insight into the key electric current effect for the grain refinement shown in chapter 3, this chapter presents a potential approach to promote the grain refinement. In addition, the solute distribution under the influence of electric current is examined based on the knowledge about the electric current effects. Moreover, the grain refinement mechanism under application of travelling magnetic field is investigated by performing a series of solidification experiments to compare with the experiments about the grain refinement mechanism driven by electric currents shown in chapter 4. Chapter 6 summarizes the main conclusions from the presented work.

There are great energy savings to be made by recycling aluminium; as little as 5% of the energy needed for primary aluminium production may be required. Striving to produce high quality aluminium castings requires knowledge of microstructural imperfections, which is extra important when casting recycled aluminium that generally contains higher levels of imperfections compared to primary aluminium. Imperfections include amongst others Si, Fe, and Mn as well as oxides. Si is needed for castability, but it may also initiate fracture. There are different types of Fe-rich intermetallics influencing properties of castings, generally in a negative direction. Oxides constitute cracks and they are elusive because they are difficult to quantify. This thesis aims to increase knowledge about imperfections in recycled aluminium castings originating from alloying elements and the melt. Experiments were performed in advanced laboratory equipment, including X-radiographic imaging during solidification and in-situ tensile testing in a scanning electron microscope. Experiments were also performed at industrial foundry facilities. The experiments showed that the nucleation temperature of primary α-Fe intermetallics increased with higher Fe, Mn, and Cr contents. Primary α-Fe are strongly suggested to nucleate on oxides and to grow in four basic morphologies. Lower nucleation frequency of α-Fe promoted faster growth and hopper crystals while higher nucleation frequency promoted slower growth rates and massive crystals. Results also showed that a decrease in the size of the eutectic Si and plate-like β-Fe intermetallics improved tensile properties, foremost the elongation to fracture. In β-Fe containing alloys the transversely oriented intermetallics initiated macrocracks that are potential fracture initiation sites. In alloys with primary α-Fe foremost clusters of intermetallics promoted macrocracks. In fatigue testing, a transition from β-Fe to α-Fe shifted the initiation sites from oxides and pores to the α-Fe, resulting in a decrease of fatigue strength. Oxides in Al-Si alloys continue to be elusive; no correlations between efforts to quantify the oxides and tensile properties could be observed. / Genom att återvinna aluminium kan stora energibesparingar göras eftersom återvinning kan förbruka så lite som 5% av den energi som behövs för produktion av primär aluminium. Vid gjutning av högkvalitativa aluminiumprodukter krävs förståelse för defekter i mikrostrukturen och denna kunskap är extra viktig vid användning av återvunnen aluminium, som i regel innehåller mer defekter än primär aluminium. Defekterna består bland annat av Si, Fe och Mn samt oxider. Si behövs för gjutbarhet men kan också initiera brott. Järnrika intermetaller kan ha olika morfologier som generellt påverkar gjutna komponenter negativt. Oxider, som kan utgöra sprickor, är gäckande då de är svåra att kvantifiera. Denna avhandlings syfte är att öka kunskapen om defekter i gjutna komponenter av återvunnen aluminium. Experiment utfördes med avancerad laborationsutrustning så som röntgenfotografering av prover under stelning och dragprovning i svepelektronmikroskop. Experiment utfördes också i industrimiljö. Experimenten visade att kärnbildningstemperaturen steg för primära α-Fe intermetaller med ökade andelar av Fe, Mn och Cr. Resultaten tyder starkt på att primär α-Fe kärnbildas på oxider och att de växer i fyra olika morfologier. Lägre kärnbildningstäthet av α-Fe främjade snabbare tillväxt av kristaller med håligheter men högre kärnbildningstäthet främjade långsammare tillväxt av massiva kristaller. Resultaten visade också att minskad storlek av eutektiskt Si och β-Fe intermetaller ledde till förbättring av dragprovsresultaten, främst brottförlängningen. I legeringar med β-Fe ledde transversellt orienterade intermetaller till makrosprickor vilka kan initiera brott. I legeringar med primär α-Fe var det främst kluster av intermetaller som orsakade makrosprickor. I utmattningsprovning orsakade modifiering av β-Fe till α-Fe förflyttning av sprickinitieringen från oxider och porer till α-Fe, vilket resulterade i en reducerad utmattningshållfasthet. Oxiderna i Al-Si-legeringar fortsätter att gäcka; ingen korrelation mellan försök att kvantifiera oxiderna och draghållfasthet kunde påvisas.

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The present thesis investigates the grain refinement in solidifying Al-7wt%Si hypoeutectic alloy driven by electric currents. The grain size reduction in alloys generated by electric currents during the solidification has been intensively investigated. However, since various effects of electric currents have the potential to generate the finer equiaxed grains, it is still argued which effect plays the key role in the grain refinement process. In addition, the knowledge about the grain refinement mechanism under the application of electric currents remains fragmentary and inconsistent. Hence, the research objectives of the present thesis focus on the role of electric current effects and the grain refinement mechanism under the application of electric currents. Chapter 1 presents an introduction with respect to the subject of grain refinement in alloys driven by electric current during the solidification process in particular, including the research objectives; the research motivation; a brief review about the research history; a short introduction on the electric currents effects and a review relevant to the research status of grain refinement mechanism. Chapter 2 gives a description of research methods. This chapter shows the employed experiment materials, experimental setup, experimental procedure, the analysis methods of solidified samples, and numerical method, respectively. Chapter 3 focuses on the role of electric current effects in the grain refinement process. A series of solidification experiments are performed under various values of effective electric currents for both, electric current pulse and direct current. The corresponding temperature measurements and flow measurements are carried out with the increase of effective electric current intensity. Meanwhile, numerical simulations are conducted to present the details of the flow structure and the distribution of electric current density and electromagnetic force. Finally, the role of electric current effects is discussed to find the key effect in the grain refinement driven by electric currents. Chapter 4 investigates the grain refinement mechanism driven by electric currents. This chapter mainly focuses on the origin of finer equiaxed grain for grain refinement under the application of electric current on account of the importance of the origin for understanding the grain refinement mechanism. A series of solidification experiments are carried out in Al-7wt%Si alloy and in high purity aluminum. The main origin of equiaxed grain for grain refinement is concluded based on the experiment results. Chapter 5 presents three further investigations based on the achieved knowledge in chapter 3 and 4 about the role of electric current effects and the grain refinement mechanism. According to the insight into the key electric current effect for the grain refinement shown in chapter 3, this chapter presents a potential approach to promote the grain refinement. In addition, the solute distribution under the influence of electric current is examined based on the knowledge about the electric current effects. Moreover, the grain refinement mechanism under application of travelling magnetic field is investigated by performing a series of solidification experiments to compare with the experiments about the grain refinement mechanism driven by electric currents shown in chapter 4. Chapter 6 summarizes the main conclusions from the presented work.:Abstract VII Contents IX List of figures XI List of tables XVII 1. Introduction 1 1.1 Research objectives 1 1.2 Research motivation 2 1.3 Research history 5 1.4 Electric currents effects 9 1.4.1 Some fundamentals 10 1.4.2 Role of electric currents effects in grain refinement 12 1.5 Grain refinement mechanism 13 1.5.1 Nucleation theory 13 1.5.2 Equiaxed grain formation without the application of external fields 18 1.5.3 Grain refinement mechanism under the application of electric currents 23 1.5.4 Grain refinement mechanism under the application of magnetic field 29 2. Research methods 31 2.1 Introduction 31 2.2 Experimental materials 31 2.2.1 Solidification 31 2.2.2 Similarity of GaInSn liquid metal and Al-Si melt 32 2.3 Experimental setup 33 2.3.1 Solidification 33 2.3.2 Flow measurements 35 2.3.3 External energy fields 36 2.4 Experimental procedure 38 2.4.1 Solidification 38 2.4.2 Flow measurements 39 2.5 Metallography 39 2.6 Numerical method 41 2.6.1 Numerical model 41 2.6.2 Numerical domain and boundary conditions 42 3. Role of electric currents effects in the grain refinement 45 3.1 Introduction 45 3.2 Experimental parameter 45 3.3 Results 46 3.3.1 Solidified structure 46 3.3.2 Forced melt flow 50 3.3.3 Temperature distribution 58 3.4 Discussion 61 3.5 Conclusions 67 4. Grain refinement mechanism driven by electric currents 69 4.1 Introduction 69 4.2 Experimental parameter 69 4.3 Results 73 4.3.1 Solidified structure of Al-Si alloy 73 4.3.2 Cooling curves of Al-Si alloy 77 4.3.3 Solidified structure of high purity aluminum 78 4.4 Discussion 80 4.5 Conclusions 83 5. Supplemental investigations 85 5.1 A potential approach to improve the grain refinement 85 5.1.1 Introduction 85 5.1.2 Experimental parameter 86 5.1.3 Results and discussion 87 5.2 Macrosegregation formation 90 5.2.1 Introduction 90 5.2.2 Experimental parameter 91 5.2.3 Results and discussion 92 5.3 Grain refinement driven by TMF 97 5.3.1 Introduction 97 5.3.2 Experimental parameter 97 5.3.3 Results and discussion 98 5.4 Conclusions 102 6. Summary 103 Bibliography 105

La micro fusion laser d'un lit de poudre (SLM) permet la réalisation de pièces complexes avec des microstructuresfines. Cette technologie présente de nombreux avantages mais se heurte encore à une faible disponibilité des poudres d'alliages. En SLM, la pièce est d'abord conçue par CAO (conception assistée par ordinateur), puis construite couche par couche avec un faisceau laser commandé par un ordinateur. Dans ce cadre, le travail effectué dans cette thèse a consisté à étudier et à développer une nouvelle méthode pour réaliser des pièces en alliages et en composites à partir de mélanges de poudres élémentaires, ouvrant ainsi la voie à une grande variété de compositions.Au niveau expérimental le choix s'est porté sur le système aluminium-silicium avec différentes teneurs en silicium (12, 18 et 50% en poids). L'effet de l'ajout d'un champ magnétique statique a aussi été proposé comme un outil supplémentaire de contrôle de la microstructure.Dans le processus de fabrication de pièces par SLM la puissance du laser et la vitesse de balayage déterminent au premier chef la densité, la microstructure, la composition des phases et les propriétés mécaniques du produit. Une analyse systématique de l'effet de ces paramètres sur l'alliage Al - Si fabriqué par SLM à partir de mélanges de poudres est présentée. Des alliages ont été ainsi obtenus pour plusieurs domaines de composition visés correspondant à des applications pratiques (structures légères, système tribologique, emballage électronique, ...).Les microstructures fines obtenues grâce à la solidification rapide des matériaux fondus conduit à des propriétés quise comparent de façon favorable à celles obtenues avec les techniques classiques d'élaboration et de mise en oeuvre. / As a new manufacturing technology, Selective laser melting (SLM) has a large potential in the manufacturing of complex parts with ultrafine microstructure.Selective laser melting has many significant advantages over traditional manufacturing methods but still faces a low availability of powder materials. With SLM, the part is firstly designed via 3D computer-aided design (CAD)), then built layer-by-layer with a high energy computer-controlled laser beam The work done in this study was therefore aiming at developing a new way to obtain alloys and composites directly from elemental powder mixtures with a large composition flexibility.Experimentally the choice was made of the aluminum-silicon system with several silicon contents (12, 18, 50 wt. %).Adding a static magnetic field was also considered as an additional way to control the microstructure. When parts are manufactured by SLM, laser power and scanning speed are the main parameters determining the density, microstructure, phase composition and mechanical properties. A systematic analysis of the role of these parameter on the manufacturing of Al - Si alloys by SLM from mixtures of powders was therefore conducted. Al - Si alloys with a very fine microstructure were thus obtained for several composition ranges corresponding to practical applications (lightweight structures, high wear resistance alloys, electronic packaging material, ...). The properties of the materials obtained in this way, according to the performed characterizations, compares favorably with those obtained via the conventional production technologies.

Aluminum - Silicon alloys are recognized as appropriate materials for high performance cast components used in transportation powertrain applications. A combination of excellent wear resistance, good thermal conductivity and low density make these materials good candidates for engine bore applications. It is well accepted that the tribological properties of these alloys are dictated by the presence of hard eutectic silicon particles and their distribution in the soft aluminum matrix. Three near-eutectic aluminum-silicon engine bore alloys manufactured by different processing routes such as sand casting, chill casting and spray compaction were investigated to determine the influence of solidification on evolution of microstructure of these alloys and to establish correlation of microstructure with tribological properties. The spatial distribution of the silicon particles in aluminum matrix is analyzed using various image analysis techniques and contact distribution studies. The chill cast alloy shows large columnar primary aluminum dendrites interspersed with coarse silicon particles. The sand cast and spray compacted alloys show better spatial distribution of refined silicon particles. Microstructures generated under different solidification modes are found to have varying morphologies. The crystallographic orientations of the dendritic and eutectic aluminum as well as that of the eutectic silicon were studied using electron backscatter diffraction (EBSD). The eutectic silicon nucleating in chill cast alloy is found to exhibit strong orientation relationship with the aluminum matrix. The crystallographic orientation relationship shows that the solidification modes of the eutectics in these three alloys are different, from alloy to alloy, due to their different solidification rates and due to the addition of grain refiners and modifiers. The hardness values of the aluminum matrix and silicon particles of these alloys were found using nanoindentation and micro indentation tests. Preliminary wear studies were carried out on etched and unetched test alloys in dry reciprocating sliding. The results show that of the three test alloys, the alloy in which eutectic regions nucleate heterogeneously from the primary aluminum dendrites gives the best wear resistance and the highest hardness. The very low friction coefficient recorded for the etched alloys is accounted for by the insitu formation of a thin sheet of tribofilm on the protruding silicon particles. The physical and chemical natures of this protective film are being investigated.

Les alliages aluminium-silicium (Al-Si) ont attiré une attention considérable en raison de leur importance pour les applications industrielles. Dans le présent travail, des alliages à haute pureté (Al-12.7 wt. % Si) avec et sans ajout de strontium (400 ppm), solidifiés lentement en creuset ou de façon dirigée (DS), ont été préparés et traités thermiquement. L'influence de l'ajout de strontium et des post-traitements thermiques sur les caractéristiques microstructuraux et cristallographiques des phases eutectiques a été étudiée de façon systématique. Les caractéristiques de croissance du silicium eutectique (Si) dans l'alliage non modifié ainsi que dans l'Al-12.7Si Sr-modifié ont été étudiés. Pour le cas du non-modifié, la formation répétée de variantes de macles mono-orientées permet une croissance rapide du silicium eutectique selon le mécanisme twin plane re-entrant (TPRE). Microscopiquement, les cristaux de silicium ont une forme de plaque allongée dans la direction <1 1 0> non conforme à la croissance selon <1 1 2> présumée par le modèle TPRE. L'élongation selon <1 1 0> est réalisée par des paires en zigzag <1 1 2> sur des plans de maclage parallèles, conduisant à une disparition alternative et à la création de macles rentrantes à 141°. Ce mécanisme de croissance permet aux cristaux de silicium de n'exposer que les plans {1 1 1} à faible consommation d'énergie à la consolidation. Pour les alliages modifiés au strontium, des changements importants de morphologie apparaissent dans le silicium eutectique, attribuable à la croissance de TPRE restreinte et au maclage induit par les impuretés (IIT). Ce dernier améliore la croissance latérale en formant de nouvelles macles avec des plans de macles parallèles, tandis que le second conduit à une croissance isotrope en formant des macles orientées différemment. Le traitement thermique provoque l'affinement des grains des deux phases eutectiques. L'affinement de l'α-Al se produit en même temps que la fragmentation et la sphéroïdisation du silicium et est principalement lié à la fracture des grains de silicium en raison de leur capacité limitée à accommoder la très grande dilatation thermique l'α-Al, ainsi qu'à la diffusion des atomes d'aluminium au cours du traitement thermique. La rupture du silicium génère une force de "capillarité" qui active la diffusion d'atomes d'aluminium dans la fissure. En raison du caractère de substitution de la diffusion de l'aluminium, la migration des lacunes vers l'intérieur de l'α-Al est induite lorsque l'aluminium se déplace dans les fissures, ainsi les vides de la fracture du silicium sont transférés à l'α-Al. De cette façon, les cristaux d'α-Al sont altérés et déformés. Les défauts cristallins produits, à leur tour, initient la restauration et même la recristallisation du α-Al, ce qui entraîne une diminution de taille de grain. La phase α-Al dans l'alliage de Al-12.7Si-0.04Sr solidifiée directionnellement, affiche une forte texture de fibre <1 0 0> parallèle à la direction de solidification. De très gros grains <1 0 0> α-Al sont principalement formés à la périphérie de l'échantillon cylindrique en raison des directions d'évacuation de chaleur favorables disponibles pour les trois directions [1 0 0]. Après traitement thermique, l'intensité de la texture de la phase α-Al diminue en raison de la restauration et de la recristallisation, mais le type de texture ne change pas. Pour la phase de silicium eutectique dans l'alliage de coulée, il y a deux fibres principales de texture, <1 0 0> et <1 1 0> parallèles à la direction de solidification, accompagnées de deux composantes faibles, <2 2 1> et <1 1 3> dans la même direction. Les fibres <1 0 0> et <1 1 0> correspondent à des grains de silicium situés sur la périphérie et dans le centre de l'échantillon. Les composantes <2 2 1> et <1 1 3> proviennent de plusieurs macles de grains orientés <1 1 0> et <1 0 0>. Les faibles intensités de ces deux composantes sont liées à leur fraction volumique mineure [...] / Al-Si alloys have attracted considerable attention due to their importance to industrial applications. In the present work, both crucible slowly solidified and slowly directionally solidified (DS) high-purity Al-12.7 wt. % Si alloys with and without 400 ppm Sr addition have been prepared and heat treated. The influence of Sr addition and post heat treatments on the microstructural and crystallographic features of the eutectic phases has been systematically studied. The growth characteristics of eutectic Si in the unmodified and the Sr-modified Al-12.7Si alloys were investigated. For the non-modification case, the formation of repeated single-orientation twin variants enables rapid growth of eutectic Si according to the twin plane re-entrant (TPRE) mechanism. Microscopically, Si crystals are plate-like elongated in one <1 1 0> direction that is not in accordance with the <1 1 2> growth assumed by the TPRE model. The <1 1 0> extension is realized by paired <1 1 2> zigzag growth on parallel twinning planes, leading to alternative disappearance and creation of 141° re-entrants. This growth manner ensures Si crystals to expose only their low-energy {1 1 1} planes to the melt. For the Sr-modification case, substantial changes appear in eutectic Si morphology, attributable to the restricted TPRE growth and the impurity induced twinning (IIT) growth. The first enhances lateral growth by forming new twins with parallel twinning planes, while the second leads to isotropic growth by forming differently oriented twins. Heat treatment brings about refinement of both eutectic phases. The refinement of the α-Al occurs concomitantly with the fragmentation and spheroidization of Si and is mainly related to the fracture of the Si crystals due to their limited capacity to accommodate the giant thermal expansion of the α-Al and the diffusion of Al atoms to the cracks during the heat treatment. The Si fracture generates “capillarity” force that activates the diffusion of Al atoms to the gap of the crack. Due to the substitutional feature of Al diffusion, the migration of vacancies toward the interior of the α-Al is induced when Al moves to the gaps, thus the voids of the Si fracture are transferred to the α-Al. In this way, the crystals of α-Al are distorted and defected. The produced crystal defects, in turn, initiate recovery and even recrystallization of the α-Al, resulting in grain refinement. The α-Al phase in the directionally solidified Al-12.7Si-0.04Sr alloy, displays a strong <1 0 0> fiber texture in the solidification direction. Giant <1 0 0> α-Al grains are mainly formed in the outer circle region of the cylindrical specimen due to the favorable heat evacuation directions available for the three <1 0 0> directions. After heat treatment, the texture intensity of the α-Al phase decreases due to the recovery and recrystallization, but the texture type does not change. For the eutectic Si phase in the as-cast alloy, there are two main fiber texture components, <1 0 0> and <1 1 0> in the DS direction, accompanied by two weak components, <2 2 1> and <1 1 3> in the same direction. The <1 0 0> and <1 1 0> components are from Si crystals located in the outer circle and center regions of the cylindrical specimen. The <2 2 1> and the <1 1 3> components are from multiple twins of the <1 1 0> and <1 0 0> oriented crystals. The weak intensities of these two components are related to their minor volume fraction. Once heat treated, the twinned parts with minor volume fractions enlarge at the expense of their twin related matrix, thus the <1 1 0> component is weakened and accompanied by the intensification of the components from the twins. The disappearance of the <1 1 3> component and the appearance of the <1 1 5> component are due to crystallographic rotation of Si crystals during their fragmentation

The formation of conversion coatings based on Ce, trivalent Cr and Ti/Zr is triggered by the local pH increase at cathodic IM sites of the aluminium alloy microstructure. The pH gradient is created over the cathodic intermetallic (IM) sites of the microstructure and its intensity is influenced by their activity which depends on their chemical composition, their size, and spatial distribution. Furthermore, the pre-treatment applied also affects the surface reactivity. The role of each of the microstructural features on the increased pH gradient and the subsequent triggering of local conversion coating deposition remains to be understood. To address the knowledge gap, model cast Al-Si-Fe and Al-Si-Cu-Fe alloys have been designed. Cerium based conversion coating treatment with standard parameters is applied to investigate the microstructure’s influence. Furthermore, four different surface pre-treatments’ effect on the topographical and electrochemical properties have been investigated by localized techniques and have been correlated with deposition experiment observations to prove surface reactivity. In this study, it was found that the four surface pre-treatments – polishing, NaOH, NaOH-HNO3, NaOH-H2SO4 activate the surface of alloys containing Fe-rich IM and Cu-rich IM differently. The surface pre-treatment NaOH-HNO3 was found most detrimental to the surface reactivity as the pre-treatment resulted in passivation of the IM and a drastic reduction in its volta potential. The best pre-treatment for the alloy Al-Si-Fe was found to be one with NaOH etching. In the case of Al-Si-Cu-Fe alloy, pre-treatments where a pickling step (with either H2SO4 or HNO3) was applied followed a NaOH etching step, the surface of the IM was activated more than other pre-treatments due to selective Al dealloying and Cu-redeposition. The extent of Cu-redeposition was observed to be the most when surfaces were pickled with HNO3 solution and with the NaOH- HNO3 pre-treatment, fastest deposition kinetics were observed. In the cast Al-Si-Cu-Fe alloy, the localized deposits were preferentially observed to form on only strong cathodic Cu-rich IM. The size (surface area) of the Cu-rich IM correlated linearly with the lateral deposition area as well as z-direction spread. It was found that the pH gradient resulting from the oxygen reduction reaction near an IM is very local and does not affect pH gradients of a neighbouring Cu-rich IM. The size did not have a profound impact on the extent of deposition occurring on a Cu-rich IM, but it was found that big Cu-rich IM activated faster for deposition reaction than small Cu-rich IM. When the progression of deposition on both coarse and fine microstructure cast Al-Si-Cu-Fe was quantitatively monitored at increasing conversion coating times 0.5h, 1h and 2h, it was observed that big Cu-rich IM in the coarse alloy triggered deposition faster than small Cu-rich IM. Deposition mechanism on Fe-rich IM was found to be composition specific. In the cast of big Fe-rich β-Al5FeSi IM, localized deposition initiated at the border on the IM and is explained based on Si content in the composition of the IM, which has very high resistivity. In another Fe-rich IM, although of a much smaller size, which had lower Si content and was richer in Fe, a localized deposition was observed on the entire IM. / Bildning av omvandlingsbeläggningar baserade på Ce, trivalent Cr och Ti/Zr initieras av lokalt förhöjd pH vid katodiska intermetalliska platser I aluminiumlegeringens mikrostruktur. Utbredningen av den starka pH-gradientens uppkomst över katodiska intermetalliska (IM) platser av mikrostrukturen påverkas av dess aktivitet som i sin tur beror på dess kemiska sammansättning, storlek, och rumslig fördelning. Ytans reaktivitet påverkas dessutom av dess förbehandling. Rollen av mikrostrukturens egenskaper på den förhöjda pH-gradienten och efterföljande initiering av lokal omvandlingsbeläggning återstår att förstå. För att komplettera detta kunskapsgap har Al-Si-Fe och Al-Si-Cu-Fe modellgjutlegeringar utformats. Cerium-baserade behandlingar för omvandlingsbeläggning med standardparametrar tillämpas för undersökning av mikrostrukturens påverkan. Effekten av fyra olika ytförbehandlingar på topografiska och elektrokemiska egenskaper har dessutom undersökts med lokaliserade metoder och har korrelerats med observationer vid depositionsexperient för att bevisa ytreaktivitet. I denna studie har det visats att de fyra ytförbehandlingarna – polering, NaOH, NaOH-HNO3, NaOH-H2SO4 – aktiverar ytan hos legeringar innehållande Fe-rika intermetaller och Cu-rika intermetaller på olika vis. Ytförbehandlingen med NaOH-HNO3 visades vara skadligast för ytans reaktivitet eftersom förbehandlingen resulterade i passivering av IM och en drastisk sänkning av dess volta-potential. Den bästa förbehandlingen för Al-Si-Fe-legeringen visades vara med NaOH-etsning. I Al-Si-Cu-Fe-legeringens fall, var förbehandling där ett betningssteg (antingen med H2SO4 eller HNO3) tillämpades följt av etsning med NaOH, aktiverades ytan av IM mer än med andra förbehandlingar på grund av selektiv korrosion av Al och Cu-återdeposition. Utbredningen av Cu-återdeposition observerades vara störst när ytor var betade med HNO3-lösning och depositionens kinetik var som hastigast vid förbehandling med NaOH-HNO3. I den gjutna Al-Si-Cu-Fe-legeringen observerades lokaliserade depositionerna att bildas endast på starkt katodiska Cu-rika IM. Storleken (ytarea) på de Cu-rika IM korrelerade linjärt med den laterala depositionsytan samt med spridning i z-riktning. Det visade sig att pH-gradienten som uppkom via syrereduktionsreaktionen nära IM är väldigt lokal och påverkar ej pH-gradienter vid närliggande Cu-rik IM. Storleken hade ingen anmärkningsvärd verkan på utbredningen av deposition på Cu-rik IM, men stora Cu-rika IM visade sig aktiveras snabbare för depositionsreaktion än små Cu-rika IM. När depositionens framfart över grov och fin mikrostruktur i gjuten Al-Si-Cu-Fe följdes kvantitativt vid ökande omvandlingsbeläggningstid 0,5h; 1h och 2h, så observerades att stora Cu-rika IM i den grova legeringen påbörjade depositionen snabbare än små Cu-rika IM. Depositionsmekanismen på Fe-rika IM visades vara specifik för sammansättning. I gjutgodset med stora Fe-rika β-Al5FeSi IM visades lokaliserad deposition initieras vid gränsen av IM vilket förklaras baserat på Si-halt i IM sammansättning, som har väldigt hög resistivitet. I en annan Fe-rik IM, dock av mycket mindre storlek, som hade lägre Si-halt och rikare med Fe, en lokaliserad deposition var observerad över hela IM.