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Heavily faulted Si flakes, which can be considered as crystallization products of eutectic droplets embedded in an Al matrix, were for the first time observed in an as-thixoformed A356 alloy, which contains 0.3 wt.% Sr. Large isolated particles as well as clusters of fine Si particles were observed. Evidence is provided that the faults on {111} planes of Si are not twins. Sr and Na are known to modify the morphology of the Si phase from flake to fiber morphology. Contrary to common perception, it is shown that the twin plane re-entrant edge mechanism does not operate during fiber growth. It is proposed that the modification process occurs during the nucleation of the Si phase by adsorption of modifying elements on twinned nuclei of Si. They prevent nucleus growth into stable twinned crystals, which is a prerequisite for the growth of Si flakes.

Microstructure and modification mechanisms of Si phase in as-thixoformed alloy A356