The Influence of Beryllium Incorporation into an Al-5wt.%Cu-1wt.%Si Alloy on the Solidification Cooling Rate, Microstructural Length Scale, and Corrosion Resistance

The addition of beryllium (Be) to Al–Cu alloys enhances their mechanical properties and corrosion resistance. This study aims to investigate the effects of solidification cooling rates and the addition of Be on the microstructural refinement and corrosion behavior of an Al–5wt.%Cu–1wt.%Si–0.5wt.%Be alloy. Radial solidification under unsteady-state conditions was performed using a stepped brass mold, producing four distinct cooling rates. An experimental growth law, λ2 = 26T˙−1/3, was established, confirming the influence of Be and the cooling rate on dendritic size reduction. The final microstructure was characterized by an α-Al dendritic matrix with eutectic compounds (α-Al + θ-Al2Cu + Si + Fe-rich phase) confined to the interdendritic regions. No Be-containing intermetallic phases were detected, and beryllium remained homogeneously distributed within the eutectic. Notably, Be addition promoted a morphological transformation of the Fe-rich phases from angular or acicular forms into a Chinese-script-like structure, which is associated with reduced local stress concentrations. Tensile tests revealed an ultimate tensile strength of 248.8 ± 11.2 MPa and elongation of approximately 6.4 ± 0.5%, indicating a favorable balance between strength and ductility. Corrosion resistance assessment by EIS and polarization tests in a 0.06 M NaCl solution showed a corrosion rate of 28.9 µm·year−1 and an Epit of −645 mV for the Be-containing alloy, which are lower than those measured for the reference Al–Cu and Al–Cu–Si alloys.