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Mg-containing high-Si aluminum alloys are heat-treatable alloys that are widely used in industry. Substantial attention has been paid to increasing the performance of such alloys by adding a small amount of Mn, which is an effective and common alloying element in aluminum alloys. In the present work, the solidification process of Mn-free Al-5Si-0.8Mg alloy and Al-5Si-0.8Mg-(0.45–1.97)Mn alloys are analyzed by the experimental results combined with thermodynamic calculation. The results showed that α-Al, Si, Mg2Si and π (Al8Mg3FeSi6) are predominant phases in the Mn-free Al-5Si-0.8Mg alloy while the π (Al8Mg3FeSi6) phase are transformed to α-Al(FeMn)Si phase with the addition of 0.45% Mn. With increasing Mn addition to 0.72%, the L→α-Al was replaced by L→α-Al(FeMn)Si and a primary α-Al(FeMn)Si phase appeared. Further increasing the Mn to 1.97%, the solidification reactions remained unchanged. However, the size and number of the primary α-Al(FeMn)Si phase gradually increased, while the divorced eutectic phenomenon of quaternary eutectic structure gradually weakened. Meanwhile, the Mg2Si phase in the quaternary eutectic structure gradually transformed from blocky to fine eutectic lamellar, and the quaternary eutectic structure was significantly refined. Primary blocky α-Al(FeMn)Si began to form when the Mn content was higher than 0.75%.

Phase Formation and Microstructure Evolution of Al-5Si-0.8Mg Alloys with Different Mn Concentrations