Application of X‐Ray Microtomography to Evaluate Complex Microstructure and Predict the Lower Bound Fatigue Potential of Cast Al–7(0.7)Si–4Cu–3Ni–Mg Alloys

The 3D architecture of intermetallics and porosity in two multicomponent cast Al–7(0.7)Si–4Cu–3Ni–Mg alloys is characterized using conventional microscopy and X-ray microtomography. The two alloys are found to contain intermetallic phases such as Al3Ni, Al3(NiCu)2, Al9FeNi, and Al5Cu2Mg8Si6 that have complex networked morphology in 3D. The results also show that HIPping does not significantly affect the volume fraction, size, and shape distribution of the intermetallic phases in both alloys. A novel technique similar to serial sectioning that circumvents quantification difficulties associated with interconnected particles is used to quantify the intermetallics. The largest particle size distribution is then correlated to fatigue performance using extreme value analysis to predict the maximum particle size in a sample of S-N fatigue specimens and subsequently, the lower bound fatigue life. The predictions are found to correlate well with fatigue data. The effect of HIPping on porosity characteristics is also characterized. Large pore clusters with complex morphology are observed in the unHIPped versions of both alloys, but more significant in the low Si (Al–0.7Si–4Cu–3Ni–Mg) alloy. However, these are significantly reduced after HIPping. The differences between 2D and 3D pore morphology and size distribution is discussed in terms of the appropriate pore size parameter for fatigue life prediction.