In this research, various processing conditions were implemented to enhance the mechanical properties of Al-Si alloys. The silicon content was varied from hypoeutectic (Si-10 wt.%) to eutectic (Si-12.6 wt.%) and hypereutectic (Si-14 wt.%) for the preparation of Al-XSi-3Cu-0.5Fe-0.6 Mg (X = 10–14%) alloys using die casting. Subsequently, these alloys were hot-extruded with an optimum extrusion ratio (17:1) at 400 °C to match the output extruded bar to the compressor size. An analysis of the microstructural features along with a chemical compositional analysis were carried out using scanning electron microscope along with energy dispersive X-ray spectroscopy and transmission electron microscope. The SEM micrographs of the extruded samples displayed cracks in primary Si, and the intermetallic (β-Al5FeSi) phase was fragmented accordingly. In addition, the silicon phase was homogenously distributed, and the size remained constant. The mechanical properties of the extruded samples were enhanced by the increase of silicon content, and consequently the ductility decreased. By implementing proper T6 heat treatment parameters, coherent Al2Cu phases were formed in the Al matrix, and the Si phase was gradually increased along with the silicon content. Therefore, high tensile strength was achieved, reaching values for the Al-XSi-3Cu-0.5Fe-0.6Mg (X = 10–14%) alloys of 366 MPa, 388 MPa, and 420 MPa, respectively.

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