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Aluminium alloys with Fe and Ni show potential as high castability alloys with high strength and high electrical/thermal conductivities for electric vehicle powertrains. Permanent mould castings of Al-Fe-Ni alloys with additions of Mg and Si were prepared to assess hot tearing susceptibility and mechanical properties. The electrical conductivity of the Al-Fe-Ni alloys was measured, and the Wiedemann-Franz law was used to estimate the thermal conductivity. The results show that a hot tear resistant Al-Fe-Ni alloy with composition Al-1.2Fe-0.5Mg-0.3Si-0.2Ni had an electrical conductivity of 50.91 ±0.29%IACS with yield strength, ultimate tensile strength, and elongation of 60.5 MPa, 141 MPa and 7.9%, respectively. The microstructure of the Al-Fe-Ni alloys contained primary Al, Al 9 FeNi and Mg 2 Si. The short freezing ranges and fine intermetallics allowed for good castability. The prepared Al-Fe-Ni alloys are potential new castable Al alloys that have thermal and electrical conductivity nearing wrought (6061 and 6101) compositions.

Hot tearing and mechanical properties of high electrical and thermal conductivity Al-Fe-Mg-Si-Ni Alloys