Effect of High Temperature and Thermal Cycle of 4043 Al Alloy Manufactured through Continuous Casting Direct Rolling

CCDR 4043 Al alloys are an outstanding candidate for producing mechanical components for automotive or aircraft engines. Two experimental environments—sustained high temperature and repeated heating–cooling—were simulated in the laboratory to replicate the actual operating conditions of engine components. This research investigated the microstructural evolution, mechanical properties, and fracture characteristics of the 4043 Al alloy manufactured through the continuous casting direct rolling (CCDR) process under different post-processing conditions. The CCDR process combines continuous casting, billet heating, and subsequent continuous rolling in a single equipment of production line, enabling the mass production of Al alloy in a cost-effective and energy-efficient manner. In the present work, the 4043 alloy was subjected to two environmental conditions: a sustained high-temperature environment (control group) and a cyclic heating–cooling environment (experimental group). The maximum temperature was set to 200 °C in the experiment. The experimental results show that, in a sustained high temperature working environment, the strength and elongation of the CCDR 4043 Al alloy tend to be stable. The overall effect involves the Al matrix softening and the spheroidization of eutectic Si caused by prolonged exposure to high temperature. This can enhance its ductility while retaining a certain level of mechanical strength. Comparatively, in the working environment of cyclic heating–cooling (thermal cycle), the direction of Si diffusion was different in each cycle, thus leading to the formation of an irregular Ai–Si eutectic structure containing precipitated Si particles of different sizes. The two compositions of Al and Si with very different thermal expansion coefficients may induce defects at the sharp points of Si particles under repeated heating–cooling, thereby reducing the strength and ductility of the material. The results of this work can confirm that the fracture behavior of 4043 Al alloys is obviously controlled by the morphology of the precipitated eutectic Si. In addition, CCDR 4043 Al alloys are not suitable to be used in working environments with a thermal cycle. In practical applications, it is necessary to add traces of special elements or to employ other methods to achieve the purpose of spheroidizing the precipitated eutectic Si and Al–Fe–Si phases to avoid the deterioration of strength and ductility under cyclic heating. To date, no other literature has explored the changes in the microstructure and mechanical properties of CCDR 4043 Al alloys across various time scales under the aforementioned working environments. In summary, the findings provide valuable insights into the effect of thermal conditions on the properties and behavior of CCDR 4043 Al alloys, offering potential applications for it in various engineering fields, such as the automotive and aerospace industries.