Evidence of disruption of Si-rich microstructure in engineering-lightweight Al–12.2at.%Si alloy melt above liquidus temperature

The exploration of microstructures in high temperature alloy melts is important for manufacturing of metallic components but extremely challenging. Here, we report experimental evidence of the disruption of Si-rich microstructure in engineering-lightweight Al–12.2at.%Si alloy melt at 1100 °C, via melt-spinning (MS) of Al(1−x)Si(x) (x = 0.03,0.07,0.122,0.2) alloy melts from different initial melt temperatures, 800 °C and 1100 °C, under the super-high cooling rate of ~ 10(6) °C/s, in cooperation with the small angle neutron scattering (SANS) measurement. Si particles in 1100 °C MS alloys are abnormally smaller and increased in number at Al–12.2at.%Si, compared with 800 °C MS alloys, which demonstrates the disruption of Si-rich microstructure in Al–12.2at.%Si alloy melt at 1100 °C. SANS experiment verifies that large quantities of small (0–10 nm) Si-rich microstructures and small quantities of large (10–240 nm) Si-rich microstructures exist in Al–12.2at.%Si alloy melt, and the large Si-rich microstructures disrupt into small Si-rich microstructures with increasing of melt temperature from 800 to 1100 °C. Microstructure analysis of the MS alloys indicates that the large Si-rich microstructures in Al–12.2at.%Si alloy melt are probably aggregates comprising multiple small Si-rich microstructures. This work also provides a pathway for the exploration of microstructures in other high temperature alloy melts.