Aluminium-silicon-calcium Master Alloy，Aluminium silicon calcium Alloy，AlSiCa Alloy，E FORU

**Product Datasheet: Aluminium-Silicon-Calcium Master Alloy (Al-Si-Ca Alloy)** **Version:** 1.0 | **Date:** 2025-04-02 --- ### **1. General Overview** Aluminium-Silicon-Calcium Master Alloy (Al-Si-Ca Alloy) is a specialized ternary master alloy designed for advanced grain refinement and eutectic modification in aluminium-silicon casting alloys. This alloy combines the benefits of silicon's casting characteristics with calcium's unique modification capabilities, providing superior microstructural control and enhanced mechanical properties. The synergistic effect of silicon and calcium enables precise control of both primary and eutectic phases in aluminium castings. --- ### **2. International Standards** Al-Si-Ca 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) - **Typical Master Alloy Grades:** Al-10Si-5Ca, Al-15Si-8Ca, Al-20Si-10Ca, Al-25Si-12Ca --- ### **3. Chemical Composition (Weight %)** Typical composition ranges for Al-Si-Ca master alloy: | Element | Content (%) | Role & Remarks | |---------------------|-------------------|------------------------------------------| | Silicon (Si) | 8.0 – 25.0 | Primary alloying element | | Calcium (Ca) | 3.0 – 15.0 | Modification and refining element | | Iron (Fe) | ≤ 0.25 | Impurity control | | Copper (Cu) | ≤ 0.05 | Impurity control | | Magnesium (Mg) | 0 – 1.0 | Optional addition for specific applications | | Titanium (Ti) | 0 – 0.20 | Optional grain refiner | | Other Impurities | ≤ 0.15 total | — | | Aluminium (Al) | Balance | Base metal | --- ### **4. Physical Properties** | Property | Value / Range | |---------------------------|-----------------------------------| | Density | 2.6 – 2.8 g/cm³ | | Melting Range | 575 – 850°C | | Intermetallic Phases | CaSi₂, Al₂CaSi₂, Al₄Ca, Al₂Ca | | Thermal Conductivity | 100 – 150 W/m·K | | Electrical Conductivity | 30 – 45 % IACS | | Vickers Hardness | 50 – 110 HV | | Coefficient of Thermal Expansion | 20–23 × 10⁻⁶/K | --- ### **5. Key Characteristics & Advantages** - **Dual Modification:** Simultaneously modifies both silicon and intermetallic phases - **Excellent Grain Refinement:** Produces fine, uniform microstructure in castings - **Improved Fluidity:** Enhanced mold filling characteristics - **Reduced Porosity:** Minimizes gas and shrinkage defects - **Wear Resistance:** Hard calcium-silicon compounds enhance abrasion resistance - **Cost-Effective:** Economical alternative to multiple separate additions --- ### **6. Product Applications** - **Engine Blocks:** Cylinder liners, engine block castings - **Piston Alloys:** High-performance automotive and diesel pistons - **Brake Components:** Brake calipers, rotors, and related parts - **Wear-Resistant Parts:** Bushings, bearings, and sliding components - **Electrical Rotors:** Motor rotors requiring good castability - **General Engineering:** Machine parts, structural components - **Recycling:** Improvement of secondary aluminium alloys --- ### **7. Available Forms** - **Master Alloy:** Ingots, notch bars, waffle plates - **Special Forms:** Granules, powder for specific applications - **Standard Sizes:** 5–15 kg ingots - **Custom Ratios:** Tailored Si:Ca ratios for specific requirements --- ### **8. Technical Guidelines for Use** - **Addition Rate:** 0.5–3.0% master alloy to the melt - **Melt Temperature:** 720–780°C - **Holding Time:** 20–45 minutes for complete reaction - **Stirring:** Gentle mechanical stirring recommended - **Treatment Window:** Optimal effectiveness within 30–90 minutes - **Cooling Rate:** Controlled solidification for optimal structure --- ### **9. Modification Performance** | Application | Si:Ca Ratio | Grain Size Reduction | Porosity Reduction | Mechanical Property Improvement | |-------------|-------------|---------------------|-------------------|-------------------------------| | **Hypoeutectic Alloys** | 2:1–3:1 | 40–60% | 30–50% | 20–35% | | **Eutectic Alloys** | 1.5:1–2:1 | 50–70% | 40–60% | 25–40% | | **Hypereutectic Alloys** | 1:1–1.5:1 | 60–80% | 50–70% | 30–45% | --- ### **10. Comparison with Other Modifiers** | Modifier Type | Silicon Modification | Grain Refinement | Cost | Environmental Impact | |---------------|---------------------|------------------|------|---------------------| | **Al-Si-Ca** | Excellent | Very Good | Medium | Favorable | | **Al-Sr** | Excellent | Poor | High | Moderate | | **Al-Na** | Good | Poor | Low | Concerns | | **Al-Sb** | Good | Fair | Medium | Favorable | --- ### **11. Metallurgical Mechanisms** - **Calcium Function:** Forms CaSi₂ compounds that modify silicon morphology - **Silicon Function:** Provides casting characteristics and hard phase formation - **Synergistic Effect:** Combined action produces finer, more uniform microstructure - **Nucleation Sites:** Calcium-containing compounds act as potent nucleation sites - **Phase Control:** Modifies both primary and eutectic solidification --- ### **12. Quality Control Parameters** - Precise Si:Ca ratio control (±0.2%) - Homogeneous distribution of intermetallic phases - Consistent modification efficiency - Low gas content (hydrogen < 0.15 ml/100g) - Chemical composition certification --- ### **13. Health, Safety & Handling** - **Calcium Reactivity:** Calcium can react with moisture - store in dry conditions - **Dust Control:** Avoid inhalation of fine particles during processing - **Personal Protection:** Standard foundry PPE required - **Ventilation:** Adequate fume extraction recommended - **Storage:** Sealed containers in dry environment - **Disposal:** Follow standard metal disposal protocols --- ### **14. Economic Considerations** - **Cost Efficiency:** More economical than separate silicon and calcium additions - **Process Savings:** Reduced processing time and energy consumption - **Yield Improvement:** Higher element recovery compared to individual additions - **Quality Benefits:** Improved casting yield and reduced scrap rates --- ### **15. Research & Development Trends** - **Optimized Ratios:** Research on ideal Si:Ca ratios for specific alloy systems - **Nanoscale Modification:** Control of modified phase distribution at nanoscale - **Composite Applications:** Al-Si-Ca based composites with enhanced properties - **Recycling Applications:** Improved quality of recycled aluminium alloys - **Additive Manufacturing:** Development of specialized powders for 3D printing --- ### **Disclaimer** This information is provided for technical reference only. Properties and performance may vary based on specific application conditions, processing parameters, and base alloy composition. The optimal Si:Ca ratio and addition rate should be determined for each specific application. Users are advised to conduct thorough testing to determine suitability for their processes. Always follow good foundry practices and safety guidelines, particularly regarding calcium's reactivity with moisture.

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 2310 gallon liquid totes Special package is available on request.