Modification of Silicon Microsegregation in Solid-Solution-Strengthened Ductile Iron by Alloying with Aluminum

In solid-solution-strengthened ferritic ductile iron (SSFDI), a silicon content above 4.3 wt% leads to an abrupt decrease in ultimate tensile strength and elongation at fracture. This phenomenon has recently been proven to be attributed to the formation of iron–silicon long-range orderings that lead to an embrittlement of the material. It is assumed that the local tendency to form silicon superstructures is promoted in particular by the occurrence of silicon microsegregation. During solidification of ductile iron, silicon segregates inversely into the austenite. Thus, the highest silicon concentration is larger than the initial concentration of the melt and is located directly at the graphite nodules. As a straight consequence, the presence of silicon superstructures is expected primarily in these areas. Therefore, the focus is on homogenization of the silicon microsegregation profile in order to avoid the formation of brittle iron–silicon superstructures. For this purpose, in the present study the alloying concept of SSFDI is adapted. Thermodynamic–kinetic simulations as well as experimental investigations indicate that aluminum concentrations of approx. 1.2 wt% lead to an inversion of the silicon microsegregation. The findings provide a promising tool to shift the silicon embrittlement in SSFDI to higher silicon concentrations. This method could be used to increase the maximum strength, to improve toughness properties or to increase the process integrity against deviations in silicon content.