Description:TITLE

METHOD AND SYSTEM FOR MANUFACTURING HYPEREUTECTIC ALUMINUM-SILICON ALLOY WITH ENHANCED MECHANICAL PROPERTIES

FIELD OF THE INVENTION

[0001] The present invention relates to the field of metallurgy, specifically to the synthesis and processing of hypereutectic aluminum-silicon alloys. More particularly, it pertains to a method and system for manufacturing an improved version of the B390 alloy, which is used in high-performance engine components such as cylinder blocks, liners, and pistons, with an emphasis on enhancing its mechanical properties through specific material selection, melting, modification, casting, and heat treatment processes.

BACKGROUND

[0002] Hypereutectic aluminum-silicon alloys, such as B390, are widely utilized in high-performance automotive and aerospace applications due to their superior wear resistance, high strength-to-weight ratio, and excellent thermal conductivity. B390 alloy, in particular, is commonly employed in the production of engine components such as cylinder blocks, liners, and pistons, where durability and performance under extreme conditions are critical.
[0003] Traditional methods of manufacturing B390 alloy often face challenges related to the microstructure of the material, especially the size and distribution of primary silicon particles. Large and agglomerated primary silicon particles can lead to poor mechanical properties, including reduced tensile strength and hardness. The presence of impurities and gas porosity during the alloying process further compromises the quality of the final product.
[0004] In an effort to address these issues, the present invention introduces a refined method and system for producing B390 alloy, which incorporates optimized material selection, advanced degassing techniques, and precise control of the casting and heat treatment processes. The invention also introduces a modification process using phosphorus and Ti-based master alloys, which effectively refines the silicon crystal structure, leading to enhanced mechanical properties of the alloy. By employing this novel approach, the invention aims to produce B390 alloy components with superior mechanical characteristics and consistent quality, meeting the rigorous demands of modern industrial applications.

SUMMARY

[0005] The present embodiment provides a novel method and system for manufacturing an improved hypereutectic aluminium-silicon alloy B390, which is particularly suitable for high-performance engine components such as cylinder blocks, liners, and pistons. The invention addresses the challenges associated with traditional B390 alloy production by introducing a comprehensive process that ensures enhanced mechanical properties and consistent microstructure quality.
[0006] An embodiment includes selecting and combining a plurality of alloying elements, including pure aluminum (75-80%), silicon (16-18%), copper (4-5%), magnesium (0.5-1%), and iron (1-2%). The mixture is then melted at approximately 750°C to ensure complete dissolution of the elements. To remove impurities and gases, the molten alloy undergoes a degassing process, typically using nitrogen or argon purging.
[0007] According to an embodiment, a modifier such as sodium or strontium is added to the alloy. This modification refines the silicon crystal structure, significantly improving the mechanical properties of the B390 alloy. The molten alloy is then cast into molds using techniques such as sand casting, permanent mold casting, or die casting.
[0008] According to a preferred embodiment, the cast alloy is further enhanced through a T6 heat treatment process, which includes solution heat treatment, quenching, and artificial aging. This process optimizes the alloy's strength and durability. Additionally, the invention incorporates the use of phosphorus and Ti-based master alloys to refine and homogenize the primary silicon particles, according to the "duplex nucleation" theory. This results in a uniform microstructure with fine, well-dispersed silicon particles, thereby eliminating detrimental clustering.
[0009] The final product undergoes machining and finishing to achieve the desired dimensions and surface quality, making it suitable for high-performance applications.
[0010] In summary, the present embodiment offers a robust and efficient process for producing an improved version of the B390 alloy with superior mechanical properties, making it an ideal choice for demanding industrial applications.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0012] Figure 1: Illustrates the optical microstructure of the B390 aluminum-silicon alloy.
[0013] Figure 1(a): Shows the microstructure of the unmodified B390 alloy, highlighting the presence of large, agglomerated polygonal primary silicon particles.
[0014] Figure 1(b): Depicts the microstructure of the modified B390 alloy, demonstrating the refined and uniformly dispersed primary silicon particles achieved through the modification process using phosphorus and Ti-based master alloys.
[0015] Figure 2: Presents the Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS) elemental mapping of silicon in the B390 aluminum-silicon alloy.
[0016] Figure 2(a): Displays the distribution of silicon in the B390 alloy before modification, showing clustered and irregular silicon particles.
[0017] Figure 2(b): Illustrates the improved distribution and refinement of silicon particles after the modification process, resulting in a more homogeneous microstructure with consistent silicon refinement.
[0018] These drawings collectively provide a visual comparison between the unmodified and modified B390 alloy microstructures, emphasizing the effectiveness of the modification process in enhancing the alloy's mechanical properties.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Reference will now be made in detail to present embodiments of the disclosure, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the disclosure.
[0020] Figure 1 illustrates the optical microstructure of B390 Al-Si alloy: The optical microstructure analysis of B390 Al-Si alloy provides critical insights into the distribution and morphology of silicon particles within the alloy matrix. This analysis is essential for understanding how modifications to the alloy's composition and treatment processes impact its mechanical properties and performance.
[0021] Figure 1(a) illustrates the unmodified alloy: This micrograph shows the distribution of primary silicon particles in the as-cast, unmodified B390 alloy. The silicon particles are typically coarse and irregularly shaped, which can detrimentally affect the alloy's mechanical properties.
[0022] In the unmodified B390 alloy, the silicon particles are large, polygonal, and unevenly distributed. These coarse particles can act as stress concentrators, leading to reduced tensile strength and ductility. The matrix surrounding the silicon particles is relatively unrefined, with potential micro segregations that can further impair mechanical performance.
[0023] Figure 1(b) illustrates a modified alloy according to an embodiment. This micrograph depicts the microstructure of the B390 alloy after modification with Phosphorus and Ti-based master alloys. The treatment results in finer, more uniformly distributed silicon particles, enhancing the alloy's mechanical properties and wear resistance.
[0024] Post-modification, the silicon particles are significantly refined, appearing as fine, globular, and evenly dispersed throughout the aluminium matrix. This refinement is achieved through the introduction of Phosphorus and Ti-based master alloys, which promote duplex nucleation and hinder the growth of silicon particles. The aluminium matrix in the modified alloy is more homogeneous, contributing to improved mechanical properties such as increased hardness and tensile strength
[0025] Figure1 of the illustrated embodiment demonstrates the impact of Microstructural modification. Essentially, the refinement of silicon particles in the B390 alloy through Phosphorus and Ti-based modification results in:
• Enhanced Tensile Strength: Finer silicon particles reduce stress concentration points, increasing the overall tensile strength of the alloy.
• Improved Ductility: A more uniform distribution of silicon particles allows the alloy to deform more evenly under stress, improving ductility.
• Increased Wear Resistance: The homogeneous and refined microstructure enhances the wear resistance of the alloy, making it suitable for high-stress applications such as pistons in automotive and aerospace industries.
[0026] By controlling the microstructure through precise alloy treatment processes, embodiments disclosed ensure the production of high-performance pistons, addressing the limitations of traditional casting methods and providing a significant advancement in metallurgical manufacturing techniques.
[0027] Figure 2 illustrates, via Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS) elemental mapping of silicon (Si) in B390 Al-Si alloy, the distribution and concentration of silicon (Si) within the alloy according to an embodiment. This analysis is crucial for evaluating the effectiveness of the modification processes in refining the silicon particles and ensuring their uniform distribution.
[0028] Figure 2(a) illustrates the unmodified alloy. This image shows the elemental mapping of silicon in the as-cast, unmodified B390 alloy. The silicon particles appear as large, concentrated areas within the aluminium matrix. Further, SEM/EDS mapping reveals large, irregular clusters of silicon particles. These clusters are unevenly distributed, with significant variations in particle size and concentration. The silicon particles in the unmodified alloy are not uniformly dispersed, leading to areas of high silicon concentration that can adversely affect the mechanical properties of the alloy.
[0029] Figure 2(b) illustrates the modified alloy according to an embodiment. The image depicts the elemental mapping of silicon in the B390 alloy after treatment with Phosphorus and Ti-based master alloys. The silicon particles are more finely distributed and less concentrated, indicating a more uniform microstructure. Further, SEM/EDS mapping shows a significant refinement in the size and distribution of silicon particles. The particles are smaller, more globular, and evenly dispersed throughout the aluminium matrix. The modified alloy exhibits a much more homogeneous distribution of silicon particles, with no large clusters or areas of high concentration. This uniform distribution is achieved through the introduction of Phosphorus and Ti-based master alloys during the alloy treatment process.
[0030] Embodiments disclosed reveal the Impact of Silicon Refinement on Alloy Properties, namely:
• Enhanced Mechanical Properties: The refined and uniformly dispersed silicon particles reduce stress concentration points, increasing the tensile strength and ductility of the alloy.
• Improved Wear Resistance: A more homogeneous silicon distribution enhances the wear resistance of the alloy, making it more suitable for high-performance applications.
• Better Performance under Stress: The uniform microstructure ensures that the alloy can better withstand high-stress conditions without significant degradation in mechanical properties.
[0031] SEM/EDS elemental mapping validate the improvement in microstructural characteristics achieved through the alloy modification process. This advanced analytical technique confirms the successful refinement and homogenization of silicon particles, ensuring the production of high-quality pistons from an improved version of hypereutectic B390 alloy with superior performance characteristics.
[0032] The present embodiment provides a detailed method and system for manufacturing the hypereutectic aluminium-silicon alloy, which is specifically designed to improve the mechanical properties and consistency of the alloy. The preferred embodiment is described as follows:

Method and System for Manufacturing Hypereutectic Aluminum-Silicon Alloy B390

1. Material Selection

[0033] According to an embodiment, the B390 alloy is composed of a carefully selected combination of elements that work together to provide the desired mechanical properties, such as strength, wear resistance, and thermal stability. The specific composition is as follows:
• Aluminum (75-80% by weight): The primary component of the alloy, providing a lightweight and corrosion-resistant matrix.
• Silicon (16-18% by weight): A critical component for increasing the hardness and wear resistance of the alloy. The high silicon content also improves the alloy’s fluidity and castability.
• Copper (4-5% by weight): Added to enhance the strength and hardness of the alloy, particularly after heat treatment.
• Magnesium (0.5-1% by weight): Contributes to the alloy’s strength and improves the heat treatability of the material.
• Iron (1-2% by weight): Helps in improving the strength and rigidity of the alloy, while also reducing casting defects.
[0034] These elements are selected for their specific roles in contributing to the alloy's overall performance, particularly in high-stress, high-temperature environments. The careful balance of these elements ensures that the B390 alloy exhibits the necessary mechanical properties for use in demanding applications such as automotive engine components.

2. Melting Process

[0035] During this process, the selected raw materials—aluminum, silicon, copper, magnesium, and iron—are introduced into a furnace and heated to approximately 750°C (1382°F). This temperature is carefully controlled to ensure that all elements are completely dissolved, avoiding the formation of unwanted phases or compounds that could negatively impact the alloy’s properties.
[0036] According to a preferred embodiment, the molten alloy is maintained at this temperature to allow for the complete integration of the elements, resulting in a uniform liquid alloy. This thorough melting is essential for achieving the desired microstructure and mechanical properties in the final cast product. The consistent temperature control also helps in minimizing oxidation and other impurities that could affect the alloy's quality. Overall, the melting process sets the foundation for the subsequent stages, such as degassing, modification, and casting, ensuring that the improved B390 alloy meets the stringent requirements for high-performance applications.

3. Degassing

[0037] During the melting process, aluminum can absorb hydrogen from moisture in the atmosphere or from the surrounding environment. If this hydrogen is not removed, it can form gas bubbles within the metal as it cools and solidifies, leading to porosity, weakened structural integrity, and reduced mechanical properties. An embodiment includes a gas purging method, wherein an inert gas such as nitrogen or argon is introduced into the molten metal through a lance or a porous plug. The gas bubbles rise through the melt, capturing dissolved hydrogen and other impurities, which are then carried to the surface and removed.
[0038] An alternate embodiment includes a rotary degassing technique comprising a rotating impeller that injects the inert gas into the molten metal. The rotation creates smaller gas bubbles, which increases the surface area contact with the melt, enhancing the removal of hydrogen and impurities more effectively.
[0039] By removing gas inclusions, the resulting metal has a more uniform and dense structure, leading to better mechanical properties such as strength and ductility. Degassed metal tends to have a smoother surface, which is essential for components requiring precision and aesthetic quality. The process minimizes casting defects such as porosity and blowholes, which can compromise the performance and lifespan of the final product.
[0040] Effective degassing ensures that the final alloy has the desired mechanical properties and is free from defects, making it suitable for critical applications like engine components.

4. Modification Process:
[0041] The primary focus of modification is to refine the silicon particles present in the hypereutectic aluminum-silicon alloy, which significantly influences the alloy's characteristics.
[0042] According to an embodiment, specific elements, known as modifiers, are added to the molten B390 alloy. Common modifiers include sodium (Na), strontium (Sr), or in advanced processes, Phosphorus (P) and Titanium (Ti)-based master alloys. These elements alter the morphology of the silicon particles in the alloy. In unmodified B390 alloy, the primary silicon particles tend to be large, polygonal, and unevenly distributed, which can negatively affect the alloy's mechanical properties. The modifiers act to refine these silicon particles, transforming them into finer, more globular shapes. This refinement results in a more uniform distribution of silicon throughout the alloy, which is critical for improving its strength, ductility, and wear resistance.
[0043] The modification process employs the "duplex nucleation" theory, particularly when using Phosphorus and Ti-based master alloys. This approach helps in the simultaneous refinement of primary silicon particles and the a-Al dendrites, leading to a more homogenous microstructure. During the modification process, the molten alloy is maintained at an optimum temperature and holding time in an electric resistance furnace. This controlled environment ensures that the modifiers are fully effective in refining the silicon particles and stabilizing the modified microstructure.
[0044] Refinement of silicon particles leads to improved hardness, tensile strength, and overall durability of the B390 alloy. A more uniform microstructure improves the alloy's fluidity and castability, making it easier to produce complex and high-precision components. The process minimizes the occurrence of casting defects such as shrinkage and cracking, ensuring higher quality and reliability of the final products.

5. Casting Process:
[0045] The improved B390 alloy is first prepared by melting a combination of pure aluminum, silicon, and other alloying elements like copper, magnesium, and iron in precise proportions. The molten alloy is then subjected to degassing and modification to remove impurities and refine the microstructure.
[0046] Molds are prepared based on the specific casting method being used. For B390 alloy, common casting techniques include: A mold made of sand, which is ideal for producing complex shapes but may have a rough surface finish. Alternatively, metal molds are used, which offer better surface finish and dimensional accuracy compared to sand casting. High-pressure die casting (HPDC) is commonly employed for B390 alloy, providing excellent surface finish, dimensional accuracy, and production efficiency.
[0047] Embodiments disclosed include High-pressure die casting for high precision, suitable for mass production, making it an efficient method for producing complex B390 alloy components. The casting process, particularly when combined with proper heat treatment, enhances the alloy’s mechanical properties, making it ideal for high-performance applications. Different casting methods can be employed based on the specific requirements of the component, offering flexibility in production. The casting process for B390 alloy is a meticulously controlled procedure that transforms the molten alloy into high-quality, durable components, ready for use in demanding industrial applications.

6. Heat Treatment:

[0048] Heat treatment methods significantly impact the alloy's mechanical properties and performance.
[0049] Solution Heat Treatment: The first step in heat treatment is solution heat treatment, where the cast B390 alloy is heated to a temperature of approximately 540°C (1004°F). The purpose of this step is to dissolve soluble phases into a single-phase solution, homogenizing the alloy's microstructure. The alloy is typically held at this temperature for 2-4 hours, allowing sufficient time for the elements like copper, magnesium, and silicon to dissolve uniformly in the aluminum matrix.
[0050] Quenching: After solution heat treatment, the alloy is rapidly cooled or quenched to lock the dissolved elements in place. Quenching is usually done in water or oil, which prevents the dissolved elements from precipitating out of the solution as the alloy cools. The rapid cooling traps the alloy in a supersaturated state, which is essential for improving its strength and hardness. However, quenching can also introduce residual stresses, which are addressed in the next step.
[0051] Artificial Aging: Following quenching, the alloy undergoes artificial aging, where it is reheated to a lower temperature, typically around 155°C (311°F). This process allows controlled precipitation of the dissolved elements, which strengthens the alloy. The aging process is carefully controlled in terms of temperature and time, usually lasting between 2-4 hours, to achieve the desired mechanical properties. Aging allows the fine precipitates to form within the aluminum matrix, which impede dislocation motion, thereby increasing the alloy's hardness and tensile strength.
[0052] According to one embodiment, a stress-relieving step may be included to reduce any residual stresses introduced during quenching. This involves heating the alloy to a lower temperature, then slowly cooling it, which helps in stabilizing the structure without significantly affecting the mechanical properties. The heat treatment process significantly enhances the mechanical properties of the B390 alloy, particularly its hardness, tensile strength, and fatigue resistance, making it suitable for high-stress applications. Heat treatment helps stabilize the alloy’s microstructure, reducing the risk of dimensional changes or warping during service. The controlled precipitation of elements during aging increases the alloy's wear resistance, which is critical for components subjected to friction and wear, such as engine parts. The combination of solution treatment, quenching, and aging refines the microstructure, ensuring uniform distribution of precipitates, which contributes to the overall performance and durability of the alloy.

7. Machining and Finishing:

[0053] Machining and finishing are processes crucial for achieving precise dimensions, surface quality, and functional characteristics required for high-performance applications, such as in automotive engines. The alloy contains a significant amount of hard silicon particles, which can present challenges during machining. Therefore, specialized techniques are often employed to achieve the desired results.
[0054] Machining: Due to the presence of hard silicon particles in B390 alloy, machining requires tools made from materials like carbide or polycrystalline diamond (PCD), which offer high wear resistance. These tools help in achieving clean cuts and maintaining tool life. Computer Numerical Control (CNC) machining is commonly used for B390 alloy components to ensure high precision and repeatability. CNC machines can perform complex operations such as milling, drilling, and turning with tight tolerances. Proper lubrication and cooling are essential during the machining of B390 alloy to reduce tool wear and prevent overheating, which can lead to dimensional inaccuracies and surface defects. High-performance cutting fluids are used to improve tool life and surface finish. The machining process must be carefully controlled to achieve the desired surface roughness. Smooth surfaces are critical for components that require close contact with other parts, such as engine pistons and liners. Fine machining passes and finishing cuts are often employed to meet these requirements.
[0055] Finishing: After machining, the parts may have sharp edges or burrs that need to be removed. Deburring can be done manually or using automated processes like tumbling or abrasive flow machining to ensure smooth edges and safe handling. Depending on the application, additional surface treatments may be applied to enhance the corrosion resistance, wear resistance, or aesthetic appearance of the B390 alloy components. Common treatments include anodizing, painting, or applying protective coatings. For components that require a high surface finish, such as those in contact with moving parts, polishing is performed. This process reduces surface roughness to a minimum, ensuring low friction and high durability in service. The final dimensions of the machined and finished parts are inspected to ensure they meet the specified tolerances. This step may involve the use of precision measuring instruments like micrometres, coordinate measuring machines (CMM), and optical comparators.

8. Characterization of the Alloy:

[0056] Due to its specific composition and application requirements, thorough characterization is essential to ensure that the alloy meets the necessary standards for mechanical strength, wear resistance, and thermal stability.
[0057] Microstructural Analysis: Optical microscopy is used to examine the microstructure of the B390 alloy at various stages of production, particularly after solidification and heat treatment. This technique helps in identifying the size, shape, and distribution of primary silicon particles, as well as the aluminum matrix and any secondary phases. SEM provides a more detailed analysis of the alloy's microstructure at higher magnifications. It allows for the observation of fine details, such as the morphology of silicon particles and the presence of any microstructural defects. SEM is also used in combination with Energy Dispersive X-ray Spectroscopy (EDS) to map the elemental distribution within the alloy.
[0058] Mechanical Property Testing: Hardness tests, such as the Vickers or Rockwell methods, are performed to measure the hardness of the alloy. The results provide insight into the material's resistance to deformation, which is crucial for applications involving high wear and friction. Tensile tests are conducted to determine the alloy's tensile strength, yield strength, and elongation. These properties are critical in evaluating the material's ability to withstand mechanical stresses during operation. Fatigue testing assesses the alloy's resistance to cyclic loading, which is particularly important for engine components that undergo repetitive stress. The results indicate the material's durability and expected lifespan under operational conditions.
[0059] Chemical Composition Analysis: Inductively Coupled Plasma Optical Emission Spectroscopy (ICP-OES) or Atomic Absorption Spectroscopy (AAS) are employed to determine the precise chemical composition of the alloy. This ensures that the alloying elements are within the specified ranges, which is essential for achieving the desired mechanical and physical properties.
[0060] Thermal Analysis: DSC is used to study the thermal behavior of B390 alloy, including its melting and solidification temperatures, phase transformations, and heat treatment responses. This analysis is crucial for optimizing casting and heat treatment processes. The thermal conductivity of B390 alloy is measured to evaluate its ability to conduct heat. This property is important in applications where thermal management is critical, such as in engine components.
[0061] Characterization ensures that the B390 alloy meets the required standards and specifications for its intended application, minimizing the risk of failure in service. Understanding the alloy's properties allows for the optimization of casting, heat treatment, and machining processes, leading to better performance and cost efficiency. Characterization provides detailed insights into the alloy's behavior under various conditions, helping in the design of components that can withstand the operational demands. The characterization of B390 alloy involves a comprehensive evaluation of its microstructure, mechanical properties, chemical composition, and thermal behavior. These analyses are essential for ensuring the alloy's suitability for high-performance applications and for optimizing the production processes to achieve the best possible material performance.
[0062] Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the present disclosure, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.
[0063] This written description uses examples to disclose the present disclosure, including the best mode, and to also enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
, Claims:CLAIMS
1. A method for manufacturing a hypereutectic aluminium-silicon alloy, B390, comprising:
combining pure aluminium (75-80%), silicon (16-18%), copper (4-5%), magnesium (0.5-1%), and iron (1-2%);
melting the combined aluminium, silicon, copper, magnesium, and iron at a temperature of approximately 750°C (1382°F) to ensure the complete dissolution of all elements into a molten alloy;
degassing the molten alloy by via a gas purging process comprising an inert gas to remove impurities and gases;
modifying the silicon crystal structure by adding a modifier selected from the group consisting of sodium and strontium to refine the silicon crystals, thereby enhancing the mechanical properties of the alloy;
casting the molten alloy into a mold using a casting technique;
heat treating the cast alloy by:
solution heat treating at approximately 540°C (1004°F) for 2-4 hours;
quenching the alloy in water or oil;
artificial aging the alloy at approximately 155°C (311°F) for 2-4 hours;
machining and finishing the cast alloy to achieve the desired dimensions and surface quality.

2. The method of claim 1, wherein the degassing step comprising the gas purging process comprises purging with at least one of nitrogen and argon.
3. The method of claim 1, wherein the modifier added to refine the silicon structure is strontium.
4. The method of claim 1, wherein the casting technique comprises at least one of sand casting, permanent mold casting, and high-pressure die casting (HPDC).
5. The method of claim 1, further comprising the step of adding phosphorus and Ti-based master alloys to the molten alloy at a specific temperature and holding time, thereby refining and homogenizing the primary silicon particles and a-Al dendrites according to the duplex nucleation theory.
6. The method of claim 5, wherein the phosphorus and Ti-based master alloys eliminate the clustering of primary silicon particles and refine the average silicon particle size, resulting in homogenous microstructures and consistent silicon refinement.
7. The method of claim 1, wherein the heat treatment process involves T5 treatment, which improves the hardness and tensile strength of the B390 alloy.
8. A system for manufacturing the hypereutectic aluminium-silicon alloy, B390, comprising:
a furnace capable of heating the alloying elements to approximately 750°C;
a degassing unit that purges the molten alloy with nitrogen or argon gas;
a modification unit for adding a modifier to refine the silicon crystal structure;
a casting system that pours the molten alloy into molds using sand casting, permanent mold casting, or die casting techniques;
a heat treatment unit that performs solution heat treatment, quenching, and artificial aging at specified temperatures and durations;
a machining unit for finishing the cast parts to specified dimensions and surface quality.
9. An aluminium alloy product, characterized by a refined microstructure with fine fibrous eutectic silicon particles and equiaxed a-Al dendrites; and wherein the aluminium alloy product comprises aluminium (75-80%), silicon (16-18%), copper (4-5%), magnesium (0.5-1%), and iron (1-2%);, and a master alloy.
10. The aluminium alloy product of claim 10, wherein the master alloy is at least one of phosphorus and Ti-based master alloy.