Effect of oxide films, inclusions and Fe on reproducibility of tensile properties in cast Al–Si–Mg alloys: Statistical and image analysis

Double oxide films (hereafter: oxides), inclusions and Fe-rich phases are known to be the most detrimental defects in cast Al–Si–Mg alloys. The effects of these defects on reproducibility of tensile properties in Al–7Si–0.35Mg alloy have been investigated in this study. Four different casting conditions (low oxide—low Fe, high oxide—low Fe, low oxide—high Fe and high oxide—high Fe) were studied. In each case, 30 tensile test samples were prepared by casting in a metallic mold and machining (total of 120 tensile test samples). Results of tensile test were analyzed by Weibull three-parameter and mixture analyses. The microstructure and fracture surface of samples were studied by optical and scanning electron microscopes. Total of 800 metallography images (200 images for each experiment) were taken and analyzed by image analysis software. Finally, the relationship between tensile properties and defects characteristics was discussed. According to the results, Fe (Fe-related phases) had larger negative impact on tensile properties of the alloy compared to oxides. On the other hand, Weibull analysis revealed that the scattering of tensile properties was mainly due to the presence of oxides in microstructure. Results of image analysis showed that the shape factor and number of pores were mainly controlled by oxides and Fe, respectively. Also, there was a clear relationship between Weibull modules of UTS and El% and shape factor of pores. Furthermore, tensile properties of the examined alloy showed strong dependence to the number of pores.