The role of strain rate in microstructure evolution, deformation heterogeneity and cracking mode of high-pressure die-casting Al7Si0.2Mg alloy

The quasi-static and dynamic deformation behaviours of high-pressure die-casting (HPDC) Al7Si0.2 Mg alloy were studied in this work. Competing effects among porosities, α-Al(Fe/Mn)Si phase, eutectic phase and α-Al dendrites on strain concentration and crack propagation at different strain rates were investigated using X-ray computed tomography (CT), scanning electron microscopy (SEM), in-situ electron backscattering diffraction (EBSD), and high-resolution digital image correlation (HR-DIC). The results indicate that yield strength and ductility of Al7Si0.2 Mg alloy were improved at high strain rates compare to quasi-static loading. Weak zones, including porosities and particle interfaces, primarily contributed to deformation heterogeneity under quasi-static tension, whereas both weak zones and Al matrix played a role under dynamic loading. Moreover, crack propagation was hardly observed on porosities during dynamic deformation, thereby reducing the sensitivity of ductility to porosity. The slip and rotation of α-Al dendrites became more pronounced during dynamic deformation. As a result, the area fraction of fractured eutectic phase increased dramatically and surpassed the area fraction of α-Al(Fe/Mn)Si phase, which became the dominant factor of crack propagation during dynamic deformation.