Effect of Fe Content on the Microstructure and Properties of 5083 Aluminum Alloy

To address the challenge of controlling Fe impurity content during the recycling of aluminum alloys, this study utilized commercial 5083 aluminum alloy as a matrix to prepare alloy samples with four different Fe contents via smelting. The effects of Fe content on the microstructure, mechanical properties, and corrosion resistance of the as-cast 5083 aluminum alloy were systematically investigated. The results indicate that increasing the Fe content induces a significant morphological evolution of the Fe-rich phases, transitioning from compact Chinese-script α-Al(Fe,Mn)Si phases at low Fe levels to coarse needle-like β-AlFeSi phases. Concurrently, both the quantity and size of the second phases increase significantly. Mechanical testing reveals that the hardness of the alloy gradually rises from 67 HV to 72 HV due to second-phase strengthening. The tensile strength shows a trend of initially increasing and then decreasing, peaking at 0.45 wt.% Fe; however, excessive Fe leads to the formation of needle-like phases that cause stress concentration, resulting in a decline in tensile strength. The elongation decreases gradually with increasing Fe content, with a maximum reduction of 19.7%. Electrochemical tests show that higher Fe content increases the self-corrosion current density and decreases the capacitive loop radius, indicating a significant degradation in the alloy’s corrosion resistance. This work provides an experimental basis for the tolerance control of Fe impurities and the performance optimization of recycled 5083 aluminum alloys.