Heat-resistant Al-Fe-V-Si aluminum alloys enhanced by in-situ TiC particles have been prepared by spray forming process with suitable process parameters. Research results show that the microstructure of the as-deposited alloy is fine and homogeneous. In-situ TIC particles prevent the unstable phases from coming into being. On the other hand, the TiC particles increase the volume fraction of heat-resistant phases. So the mechanical properties of the reinforced alloy by in-situ TIC particles are better than that of Al-Fe-V-Si alloy without the TiC particles. The hot extrusion temperature is also an important parameter to be considered. It is proved better to extrude the alloy at lower temperature. The tensile strength of the alloy without TiC particles is about 435 MPa at room temperature and is about 204 MPa at 350 degrees C. However, when the alloy is enhanced by in-situ TiC particles, the strength of alloy is about 482 MPa at room temperature and is about 224 MPa at 350 degrees C.

Keywords: spray forming; Al-Fe-V-Si alloy; heat-resistant aluminum alloy; in-situ TiC particle