Aluminium is increasingly being used in the automotive industry to reduce the weight of vehicles. It is the additions of transition elements such as Mn and Cr that can be picked up during recycling, that can form dispersoid particles during homogenisation. Dispersoids play a significant role in the recrystallization and texture development for wrought Al-Mg-Si alloys by inhibiting grain boundary motion. It is therefore important to understand the precipitation kinetics of such particles. The Mn+Cr dispersoid phases are currently thought to nucleate on β'-Mg1.8Si particles via an intermediate semi-coherent precipitate denoted the u-phase. In this study, Al-Mg-Si alloys with additions of Fe and varying levels of Cr were cast to study the effect of different homogenisation regimes on the dispersoid precipitation mechanisms and final characteristics. Electron Probe Micro Analysis (EPMA) was conducted to study the inhomogeneity of elements in the cast structure and through heating to the homogenisation temperature. It was found that Mg, Si and Fe segregate towards the dendrite edges during solidification while Cr segregates towards the dendrite centre. During heating, the matrix composition of both Mg and Si decrease and increase due to precipitation of Mg+Si phases. Cr and Fe stay segregated during the heating process due to the slower diffusion rates in the face centred cubic Al matrix. Dispersoid free regions have also been observed in the microstructure correlating to the elemental segregation in the as-cast condition. Optical, scanning and transmission electron microscopy was utilised in order to study the change in dispersoid characteristics with varying homogenisation regimes and as a function of distance through a grain. With an increase in homogenisation temperature, the mean size of dispersoids increased but number density decreased. For a longer dwell time, the dispersoids remained approximately the same size but increased in volume fraction and density. Increasing the heating rate did not significantly change the dispersoid size, volume fraction or density. The dispersoids size and number density was also studied as a function of distance through a number of grains with the interplay of nucleation, growth and coarsening discussed. Both α-Al(FeCr)Si and α'-AlCrSi dispersoids were found to exist with a variety of morphologies while the α'-AlCrSi dispersoids were found to have a larger effective diameter.

Hardness measurements and Three-Dimensional Atom Probe (3DAP) were used to characterize the early stages of precipitation in three different Al-Mg-Si alloys (Al-0.50 wt%Mg-1.00 wt%Si) with different Cu contents (0.03 wt%, 0.15 wt%, or 0.80 wt% Cu). Heat treatments were chosen to simulate an industrial production line for car body-sheet material and included natural ageing (NA), pre-ageing at 80 °C (PA), paint-bake ageing at 180 °C (PB) and 10 second ageing at 180 °C (spike). The Cu content and the chosen heat treatments were found to influence the microstructural evolution of the alloy considerably. Based on the determined microstructures and matrix solute concentrations, mechanisms for the effect of NA, PA and Cu additions were proposed. NA had a deleterious effect on the PB hardening response, which was delayed dramatically after 20 minutes NA or longer. When the NA time was 1 minute, β" precipitates were formed within 30 minutes PB resulting in high hardness of the alloy. The delay with NA time was caused by a decrease in the nucleation rate of elongated precipitates during the subsequent PB. This decrease was thought to be due to a combination of a decrease in the matrix solute concentrations and clusters acting as vacancy sinks. PA before NA improved the PB response due to the formation of a high density of short elongated precipitates. Small Mg-Si clusters were detected after both NA and PA. Clusters formed during PA were found to be, on average, Mg-richer and larger than those formed during NA. Larger clusters were found to be more stable during PB and, upon PB, to grow into nucleation sites for elongated precipitates. Application of a spike before PA resulted in faster growth of clusters during PA. Growth of clusters and nucleation of short elongated precipitates during PB was found to be enhanced with increasing Cu content when no PA was given. Cu was found to be present in all precipitates and clusters in the alloy with the highest Cu content. These precipitates were thought to be precursors to the Q' phase.

Aim of the present work was to explore the possibility of improving strength of cast Mg by alloying additions, viz., Si and Zn+Al. All the alloys were produced by squeeze casting technique using squeeze pressure of 12MPa and their microstructure, tensile and corrosion properties were studied. Mg-Si system was chosen because the intermetallic compound Mg2Si possesses many desirable properties, such as, low density, high hardness, high melting point. Hence, there is scope for improving the strength of Mg by dispersion of primary Mg2Si particles. Addition of Si to Mg resulted in the formation of �-Mg, particles of primary Mg2Si and eutectic as microstructural constituents. The morphology of primary Mg2Si changed from polyhedral shaped particles to dendrites as Si content was increased from 3.57 to 5.5 wt%. Volume fraction of primary Mg2Si increased with increase in Si content. Particle size of primary Mg2Si also increased with increase in silicon content but at the same time it was found to be dependent on melt temperature, i.e., a lower particle size was obtained at higher melt temperatures. Addition of Al and Sr was made to Mg-2Si alloy in order to further increase the strength by solid solution strengthening and refinement/modification of primary Mg2Si particles/eutectic. Addition of 1.2 wt% Al to Mg-2Si alloy resulted in irregular type of morphology of Mg2Si particles and increased particle size. Addition of 0.2 wt% SrtoMg-2Si-1.2Al alloy resulted in slight refinement of primary Mg2Si particles and modification of eutectic. Addition of 0.4 wt% Sr resulted in both refinement and restoration of morphology of Mg2Si particles from irregular to polyhedral shape. This was accompanied by destruction of eutectic, and rods containing Mg, Si, Al and Sr were observed. The addition of 1.33 wt%Si to Mg resulted in improvement in 0.2%PS by about 80 MPa,UTS by about 40MPa and these values did not change much till the addition of 3.57 wt% Si. A drop in the strength values was observed at Si content of 5.5 wt%,where transition in morphology of primary Mg2Si occurred from polyhedral to dendrite. Addition of Si resulted in reduction in % elongation by about 2%. The addition of Al and Sr did not change the tensile properties of binary Mg-2Si alloy much. It was concluded that the volume fraction and size of primary Mg2Siparticles obtained with Si addition up to 3.57 wt% did not contribute much to strength and the strengthening mainly came from the eutectic present in the matrix. As Si content was increased to 5.5 wt% in order to increase the volume fraction of primary Mg2Si particles, the morphology of Mg2Si changed to dendritic type resulting in reduction in strength. Thus, the maximum increase in strength is achieved at near eutectic composition,i.e.,intheMg-1.33Sialloy,andfurtherincreaseinstrengthdoesnotseem to be feasible with this alloy system. The ductility of all the Mg-Si based alloys was also low, i.e, 0.5% elongation to fracture or less. Regarding the corrosion behaviour, the addition of Si to Mg deteriorated the corrosion resistance and the addition of Al and Sr further worsened it. Since further improvement in tensile properties did not seem feasible with Mg-Si alloy system, the focus was shifted to Mg-Zn-Al alloy system. There is scope for improvement in strength in Mg-Zn-Al alloy system by solid solution strengthening, grain refinement and precipitation hardening. It was observed that the addition of Zn and Al resulted in microstructure containing α-Mg grains and secondary phase at the grain boundary. XRD analysis showed the secondary phase to be Al5Mg11Zn4 but EDS analysis did not match with this composition. Therefore, the nature of this phase remains uncertain. Addition of 6 wt% Zn and 1 wt% Al resulted in improvement in strength as well as ductility: 0.2%PS improved by about 70 MPa, UTS by about 100 MPa and % elongation by about 7%. Addition of small amounts of Caresultedinrefinementofmicrostructurecausingimprovementinstrengthwithout much decrease in % elongation. Increase in Al content from 1 to 4 wt% resulted in increase in 0.2%PS but UTS slightly decreased, as % elongation reduced. Alloys subjected to T6 heat treatment showed improvement in strength but slight reduction in % elongation. ZA64 alloy in T6 condition gave 130 MPa 0.2%PS, 225 MPa UTS and 4.9% elongation, which are much higher tensile properties as compared Mg-Si alloys. All the three mechanisms mentioned above contribute to the strengthening. There is scope for further improvement in strength by employing a more suitable heat treatment. Regarding corrosion behaviour, addition of 6 wt% Zn and 1 wt% of Al to Mg did not deteriorate its corrosion resistance much. Addition of small amounts of Ca was found to be beneficial for corrosion resistance, whereas an increase in Al content lowered the corrosion resistance. Heat treatment also reduced the corrosion resistance.