Microstructure, mechanical properties and corrosion behavior of Rheo-HPDC a novel Al-8Si-Fe alloy

•A novel Al-8Si-Fe alloy were prepared by Rheo-HPDC.•Microstructure of the Al-8Si-Fe alloy was greatly refined by Rheo-HPDC.•Rheo-HPDC Al-8Si-Fe alloy showed improved mechanical properties and thermal conductivity.•Rheo-HPDC Al-8Si-Fe alloy showed a great improvement in corrosion resistance. Microstructure, mechanical properties and corrosion behavior of a novel Al-8Si-Fe alloy fabricated by Rheo-HPDC were investigated. Compared with the HPDC alloy, the microstructure (α1/α2-Al, Si and β-Al5FeSi phases) of the alloy was greatly refined by Rheo-HPDC. The Rheo-HPDC alloy showed improved mechanical properties and thermal conductivity to those prepared by HPDC, and the increasing rates of UTS, YS, elongation, hardness and thermal conductivity were 31%, 19%, 59%, 12% and 10%, respectively. Rheo-HPDC Al-8Si-Fe alloy also indicated a significant improvement in corrosion resistance as demonstrated by the results of immersion, electrochemical and scanning kelvin probe (SCP) tests.