Aluminium-silicon-iron Master Alloy，Aluminium silicon iron Alloy，AlSiFe Alloy，E FORU

**Product Datasheet: Aluminium-Silicon-Iron Master Alloy (Al-Si-Fe Alloy)** **Version:** 1.0 | **Date:** 2025-04-02 --- ### **1. General Overview** Aluminium-Silicon-Iron Master Alloy (Al-Si-Fe Alloy) is a specialized ternary master alloy primarily used for controlled iron addition and microstructure modification in aluminium-silicon casting alloys. This alloy enables precise introduction of iron to form beneficial intermetallic compounds while mitigating the detrimental effects of iron impurities. It is particularly valuable in secondary aluminium production and for applications requiring specific iron-containing phases for enhanced properties. --- ### **2. International Standards** Al-Si-Fe master alloys are referenced in several international specifications: - **ASTM:** ASTM B179 (Standard Specification for Aluminum Alloys in Ingot and Molten Forms) - **ISO:** ISO 209-1 (Wrought aluminium and aluminium alloys) - **EN:** EN 1676 (Aluminium and aluminium alloys - Master alloys) - **GB/T:** GB/T 8734 (Aluminium alloy master alloys) - **JIS:** JIS H 2118 (Aluminium alloy master alloys) - **Typical Master Alloy Grades:** Al-12Si-5Fe, Al-15Si-8Fe, Al-20Si-10Fe, Al-25Si-15Fe --- ### **3. Chemical Composition (Weight %)** Typical composition ranges for Al-Si-Fe master alloy: | Element | Content (%) | Role & Remarks | |---------------------|-------------------|------------------------------------------| | Silicon (Si) | 10.0 – 25.0 | Primary alloying element | | Iron (Fe) | 3.0 – 15.0 | Controlled addition element | | Manganese (Mn) | 0 – 5.0 | Optional addition for phase modification | | Copper (Cu) | ≤ 0.10 | Impurity control | | Zinc (Zn) | ≤ 0.05 | Impurity control | | Magnesium (Mg) | 0 – 1.0 | Optional addition for specific applications | | Other Impurities | ≤ 0.15 total | — | | Aluminium (Al) | Balance | Base metal | --- ### **4. Physical Properties** | Property | Value / Range | |---------------------------|-----------------------------------| | Density | 2.8 – 3.2 g/cm³ | | Melting Range | 575 – 1150°C | | Intermetallic Phases | Al₅FeSi (β-phase), Al₈Fe₂Si (α-phase), Al₃FeSi₂ | | Thermal Conductivity | 90 – 140 W/m·K | | Electrical Conductivity | 25 – 40 % IACS | | Vickers Hardness | 70 – 130 HV | | Coefficient of Thermal Expansion | 19–22 × 10⁻⁶/K | --- ### **5. Key Characteristics & Advantages** - **Controlled Iron Addition:** Precise introduction of iron in beneficial forms - **Phase Modification:** Converts detrimental iron phases to less harmful morphologies - **Wear Resistance:** Hard iron-silicon intermetallics enhance abrasion resistance - **High Temperature Stability:** Maintains properties at elevated temperatures - **Casting Performance:** Improved fluidity and reduced hot tearing - **Recycling Enhancement:** Better iron management in secondary aluminium production --- ### **6. Product Applications** - **Engine Components:** Cylinder blocks, piston alloys, engine brackets - **Brake Systems:** Brake rotors, calipers, and related components - **Wear-Resistant Parts:** Bushings, bearings, sliding components - **Electrical Applications:** Rotor castings for electric motors - **Automotive Structures:** Chassis components, suspension parts - **Recycling Industry:** Quality improvement of secondary aluminium alloys - **Tooling Applications:** Molds and dies requiring wear resistance --- ### **7. Available Forms** - **Master Alloy:** Ingots, notch bars, waffle plates - **Special Forms:** Granules, powder for specific applications - **Standard Sizes:** 5–20 kg ingots - **Custom Compositions:** Tailored Si:Fe:Mn ratios --- ### **8. Technical Guidelines for Use** - **Addition Rate:** 1.0–5.0% master alloy to the melt - **Melt Temperature:** 730–800°C - **Holding Time:** 30–60 minutes for phase equilibrium - **Stirring:** Moderate mechanical stirring recommended - **Cooling Rate:** Controlled solidification for optimal phase formation - **Manganese Adjustment:** Mn:Fe ratio of 0.5–1.0 for phase modification --- ### **9. Iron Phase Control** | Mn:Fe Ratio | Primary Iron Phase | Morphology | Impact on Properties | |-------------|-------------------|------------|---------------------| | **< 0.3** | Al₅FeSi (β-phase) | Needle-like | Detrimental - reduces ductility | | **0.3–0.6** | Mixed phases | Chinese script | Moderate - acceptable for many applications | | **0.6–1.0** | Al₈Fe₂Si (α-phase) | Compact | Beneficial - improves wear resistance | | **> 1.0** | Al₁₅(Fe,Mn)₃Si₂ | Globular | Optimal - enhances mechanical properties | --- ### **10. Mechanical Properties with Controlled Iron** | Fe Content (%) | Tensile Strength (MPa) | Elongation (%) | Impact on Wear Resistance | |----------------|---------------------|----------------|--------------------------| | **0.5–1.0** | 200–260 | 8–15 | Slight improvement | | **1.0–1.5** | 220–280 | 6–12 | Moderate improvement | | **1.5–2.0** | 240–300 | 4–9 | Significant improvement | | **> 2.0** | 260–320 | 2–6 | Major improvement | --- ### **11. Quality Control Parameters** - Precise Si:Fe ratio control (±0.2%) - Controlled Mn:Fe ratio for phase modification - Homogeneous intermetallic phase distribution - Low gas content (hydrogen < 0.18 ml/100g) - Microstructural certification for iron phases --- ### **12. Health, Safety & Handling** - **Standard Precautions:** Generally safe with standard handling procedures - **Dust Control:** Avoid inhalation of fine particles during processing - **Personal Protection:** Standard foundry PPE required - **Ventilation:** Adequate fume extraction recommended - **Storage:** Dry conditions to prevent oxidation - **Disposal:** Follow standard metal disposal protocols --- ### **13. Economic & Recycling Benefits** - **Cost Efficiency:** Enables use of higher iron content secondary aluminium - **Resource Optimization:** Better utilization of recycled materials - **Quality Consistency:** Improved reproducibility in recycled alloys - **Process Economics:** Reduced need for high-purity primary aluminium --- ### **14. Comparison with Individual Additions** | Addition Method | Phase Control | Consistency | Cost | Processing Complexity | |-----------------|---------------|-------------|------|---------------------| | **Al-Si-Fe Master Alloy** | Excellent | High | Medium | Low | | **Separate Fe + Si** | Poor | Low | Low | High | | **High-Fe Primary** | Poor | Variable | High | Medium | --- ### **15. Research & Development Trends** - **Advanced Phase Control:** Nanoscale control of intermetallic phases - **Multi-element Systems:** Complex Al-Si-Fe-Mn-Cr alloys - **Additive Manufacturing:** Specialized powders for 3D printing applications - **Recycling Technologies:** Enhanced iron management in circular economy - **Computational Modeling:** Prediction of phase formation and properties --- ### **Disclaimer** This information is provided for technical reference only. Properties and performance may vary based on specific application conditions, processing parameters, and cooling rates. Iron content and phase control require careful process management. Users are advised to conduct thorough testing to determine optimal composition and processing parameters for their specific applications. Always follow good foundry practices and safety guidelines, particularly when working with high-iron content alloys.

Packing of Standard Packing: Typical bulk packaging includes palletized plastic 5 gallon/25 kg. pails, fiber and steel drums to 1 ton super sacks in full container (FCL) or truck load (T/L) quantities. Research and sample quantities and hygroscopic, oxidizing or other air sensitive materials may be packaged under argon or vacuum. Solutions are packaged in polypropylene, plastic or glass jars up to palletized 2311 gallon liquid totes Special package is available on request.