The influence of modified intermetallics and Si particles on fatigue crack paths in a cast A356 Al alloy

Mechanical fatigue tests were conducted on uniaxial specimens machined from a cast A356‐T6 aluminium alloy plate at total strain amplitudes ranging from 0.1 to 0.8% ( R  = − 1). The cast alloy contains strontium‐modified silicon particles (vol. fract. ~6%) within an Al–Si eutectic, dispersed α intermetallic particles, Al 15  (Fe,Mn) 3  Si 2 (vol. fract. ~1%), and an extremely low overall volume fraction of porosity (0.01%). During the initial stages of the fatigue process, we observed that a small semicircular fatigue crack propagated almost exclusively through the Al–1% Si dendrite cells. The small crack avoided the modified silicon particles in the Al–Si eutectic and only propagated along the α intermetallics if they were directly in line with the crack plane. These growth characteristics were observed up to a maximum stress intensity factor of ~ K trmax  = 7.0 MPa m 1/2 (maximum plastic zone size of 96 μm). When the fatigue crack propagated with a maximum crack tip driving force above 7.0 MPa m 1/2 the larger fatigue crack tip process zone fractured an increased number of silicon particles and α intermetallics ahead of the crack tip, and the crack subsequently propagated preferentially through the damaged regions. As the crack tip driving force further increased, the area fraction of damaged α intermetallics and silicon particles on the fatigue fracture surfaces also increased. The final stage of failure (fast fracture) was observed to occur almost exclusively through the Al–Si eutectic regions and the α intermetallics.