Issues $\rightarrow$ Volume 27, Issue 3 (2026)

Cast Aluminium Alloys as Competitive Modern Structural Materials: Chemical Compositions, Fabrication, Treatment, Testing, Mechanical Properties, and Applications

LIUTYI R.V.$^{1}$, PETRYK I.Ya.$^{2}$, IVANCHENKO D.V.$^{1}$, YAMSHІNSKIJ М.М.$^{1}$, LUKIANENKO I.V.$^{1}$, BYBA I.G.$^{1,3,4}$, KYVHYLO B.V.$^{1}$, PETRYCHENKO S.V.$^{1}$, KOVALENKO V.V.$^{1}$, LEONOV D.S.$^{5}$, and BARABASH М.Yu.$^{1,4,5,6}$

$^1$E.O. Paton Education and Research Institute of Materials Science and Welding, National Technical University of Ukraine ‘Igor Sikorsky Kyiv Polytechnic Institute‘, 37 Beresteiskyi Ave., 03056 Kyiv, Ukraine
$^2$Frankivsk National Technical University of Oil and Gas, 15 Karpatska Str., 76019 Ivano-Frankivsk, Ukraine
$^3$E.O. Paton Electric Welding Institute of the N.A.S. of Ukraine, 11 Kazymyr Malevych Str., 03150 Kyiv, Ukraine
$^4$Institute of Applied Control Systems of the N.A.S. of Ukraine, 42 Academician Hlushkov Ave., 03187 Kyiv, Ukraine
$^5$Technical Centre of the N.A.S. of Ukraine, 13 Pokrovska Str., 04070 Kyiv, Ukraine
$^6$Gas Institute of the N.A.S. of Ukraine, 39 Degtyarivska Str., 03113 Kyiv, Ukraine

Received / final version: 19.05.2026 / 05.08.2026 Download PDF logo PDF

Abstract
The paper presents an overview of modern aluminium alloys, the technologies used to produce and process them, and the formation of their microstructure and properties. Currently, mechanical engineering has a trend toward the widespread use of resource-efficient, environmentally friendly, and high-precision technologies. Since aluminium alloys have low density, relatively high strength, sufficient ductility, and certain special properties (rather high strength at elevated temperatures), they are ideal materials for widespread use in the automotive, instrumentation, and aerospace industries. A classification of aluminium alloys with different groups is provided, based on the alloying elements. Analogies are drawn between the national (Ukrainian) classification of the alloys and those used in leading industrialised countries. The similarities and differences in the chemical compositions and properties of the alloys are analysed. Casting and additive manufacturing techniques for producing aluminium-alloy parts are considered. The effect of structure-forming processes during the solidification of the alloys on their phase composition and mechanical properties is shown. Various alloying elements are considered, and their effect on the microstructure and properties is analysed. Content limits for each alloying element and the main technological features of alloy melting are recommended. Alloy modification techniques are also discussed. The effect of various modifying elements on the morphology of the overall structure and the hardening phases is shown. A separate section of the paper provides an overview of various heat treatments for cast aluminium alloys. These alloys are highly sensitive to thermal effects. Therefore, selecting the appropriate heat-treatment conditions is key for a significant enhancement of the strength (sometimes, by a factor of 1.5–2.0) through the formation of additional structural (phase) constituents. In particular, machining procedures are determined for parts used under extreme conditions (high temperatures of above 300 °C, corrosive environments, etc., as in the aviation or aerospace industries). The most common intermetallic phases in the aluminium alloys are listed; the effect of each of these phases on the properties is discussed. A comparative diagram is built, which shows the mechanical properties (strength and elongation) of the alloys commonly used and those ones under development (experimental alloys). The data shown in this diagram combine the results of many years of studies conducted by researchers from various countries, which were published in leading scientific journals. The data on the strength at elevated temperatures are also presented; the mechanical properties at high temperatures (up to 450 °C) and upon prolonged exposure to extreme conditions are considered. The current scientific and technological issues, on which the experts in aluminium casting are currently working, are identified.

Keywords: aluminium-casting alloys, alloying, heat treatment, mechanical properties, structure formation, recycling.

DOI: https://doi.org/10.15407/ufm.27.03.***

Citation: R.V. Liutyi, I.Ya. Petryk, D.V. Ivanchenko, М.М. Yamshіnskij, I.V. Lukianenko, I.G. Byba, B.V. Kyvhylo, S.V. Petrychenko, V.V. Kovalenko, D.S. Leonov, and М.Yu. Barabash, Cast Aluminium Alloys as Competitive Modern Structural Materials: Chemical Composition, Properties, and Applications, Progress in Physics of Metals, 27, No. 3: ***–*** (2026)

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