Effect of Be Modification on the Oxide Bifilms and Tensile Strength Reliability of Al-Si-Mg Alloys Containing Excess Fe

The effect of oxide bifilms and Be modification (0.2 wt pct) on the tensile strength reliability of the as-cast and T₆ heat-treated Al-9Si-0.35Mg-1.5Fe alloy was investigated using Weibull analysis. For this purpose, the density of oxide bifilms in the molten alloy was intentionally increased by surface agitation. According to the results, Be modifies the β-Al₅FeSi particles to the less harmful α-Fe compounds and substantially decreases the bifilm density in the castings leading to improved tensile properties and higher reliability. Moreover, the beneficial effect of Be was found to be more in the samples containing higher amounts of bifilms. For instance, in the heat-treated condition, Be increased the Weibull modulus of the non-agitated and surface-agitated samples by 4 and 94 pct, respectively. This improvement can be attributed to the strengthening effect of Be on the young surface oxides so that they resist more against rupture when melt is subjected to the surface turbulence. The reduced pressure test and fractography investigations also confirmed the reduction of bifilm density and bifilm-related defects in Be-modified samples.