Formation of seaweed morphology and enhancing mechanical properties of an A356 alloy by directional solidification

In the present work, regular dendrite and seaweed pattern are produced by controlling the crystal orientation during directional solidification of an A356 aluminium alloy. These morphologies and growth orientation were investigated by electron backscatter diffraction (EBSD), and the results showed that the seaweed pattern mainly prevailed under the (100)[011] orientation. At the same time, the effects of seaweed pattern in the properties of A356 alloy were analysed by room temperature tensile test. It was found that the elongation and toughness of the samples reached 20 % and 36 J/m3, respectively, for the seaweed; 13 % and 24 J/m3, respectively, for the regular dendrites; and 8 % and 14 J/m3, respectively, for the cast ingot. Compared with the regular dendrite samples, the seaweed pattern obtained relatively excellent elongation and toughness. By using scanning electron microscopy (SEM), it is found that the distribution of eutectic silicon particles in seaweed morphology sample is more refined and uniform, which is the main reason for these enhancements. •Seaweed pattern are firstly formed in industrialized A356 alloy.•The seaweed patterns enhance the mechanical property (ductility and toughness).•The tip splitting of seaweed gives rise to refined and uniformed eutectic silicon.