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Three different compositions of high-Si Al alloy pipe, with a gradient structure, were produced through semi-solid rheological squeeze casting, the microstructural characteristics of which were investigated. The mechanism of gradient structure formation and the effect of acicular Fe-rich phases on liquid segregation were revealed. Meanwhile, the crystal structures of the Al4FeSi2 and Al15(Fe, Mn)3Si2 phase were elucidated. The relationship between the volume fraction of hard particles in the pipe wall and the macro-hardness was established. Wear resistance tests of the inner surfaces of the pipe walls, and tensile strength tests at different positions around the pipe walls, showed that the δ-Al4FeSi2 phase (acicular Ferich phases) reduced the wear resistance and the tensile strength of the alloy. In this study, the gradient distribution of the hard particles caused the outside of the pipe wall to have a higher tensile strength.

Rheo-Squeeze Casting of High-Silicon Aluminium Alloy Pipes with Gradient Structures and Their Mechanical Properties