About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Aluminum Alloys: Development and Manufacturing
|
| Presentation Title |
Controlling Microstructure in HPDC Aluminum Alloys with Secondary Additions Through Thermodynamic Modeling and Experimental Validation |
| Author(s) |
Deepjyoti Mukherjee, Sarvesh Saikumar, Nicklas Kaas Ishøy, Xiaolong Li, Fang Liu |
| On-Site Speaker (Planned) |
Deepjyoti Mukherjee |
| Abstract Scope |
The growing demand for lightweight, high-performance materials in electric vehicles (EVs) has renewed interest in aluminum (Al) alloys due to their strength-to-weight ratio, scalability, and cost-efficiency. To reduce production energy by up to 95%, secondary (recycled) additions are being explored. However, recycled Al introduces tramp elements like iron (Fe), which form detrimental intermetallic phases that degrade mechanical properties. Elements such as Fe, manganese (Mn), and magnesium (Mg) contribute to the formation of brittle β-phase and sludge-forming α-phase, whose morphology depends on composition and solidification conditions. This study examines how these factors influence microstructure in high-pressure die casting (HPDC) Al alloys. Scheil calculations accompanied by experimental validation, using a high-throughput setup, employed a 3D-printed holder for parallel characterization process. The results show that optimized compositional and processing choices enable the effective use of recycled content, offering a promising pathway for sustainable alloy development with controlled microstructures. |
| Proceedings Inclusion? |
Planned: Light Metals |
| Keywords |
Phase Transformations, Aluminum, Modeling and Simulation |