Effect of scandium on structure and hardening of Al–Ca eutectic alloys

The phase composition, structure and hardening of alloys in the aluminium corner of the Al–Ca–Sc system were studied in the range up to 10% Ca and up to 1% S≿. The experimental study (optical, scanning and transmission electron microscopy with electron-microprobe analysis, differential thermal analysis and hardness measurements) was combined with Thermo-Calc software simulation for the optimization of the alloy composition. It was shown that only phases of the binary systems (Al₄Ca and Al₃Sc) might be in equilibrium with the aluminium solid solution. It was shown that the (Al) + Al₄Ca eutectic had a much finer structure as compared with the Al–Si eutectic, which suggests a possibility of reaching higher mechanical properties as compared to commercial alloys of the A356 type. The influence of the annealing temperature within the range up to 600 °C on the structure and hardness of the Al–Ca–Sc experimental alloys was studied. It was determined that the maximum hardening corresponded to the annealing at 300 °C, which was due to the precipitation of Al₃Sc nanoparticles with their further coarsening. With an example of an Al-7.6% Ca-0.3% Sc model experimental alloy, a principal possibility of manufacturing aluminium casting alloys based on the (Al) + Al₄Ca eutectic was demonstrated. Unlike commercial alloys of the A356 type, the model alloy does not require quenching, as hardening particles are formed in the course of annealing of casting. - Highlights: • Al–Ca–Sc phase diagram in aluminum corner. • Formation of Al₃Sc nanoparticles in eutectic (Al) + Al₄Ca during heating at 300–450 °C. • Hardening and thermal stability of proposed (Al–Ca–Sc) and commercial (Al–Si–Mg, 356 type) eutectic alloys