Ameliorating the high-temperature performance of cast Al-Si alloys used as engine components is essential. The effects of different T6 heat-treatment processes on the microstructure and mechanical properties of cast Al-Si-Cu-Mg-Ni-Cr alloys were investigated in the present study. The results demonstrate that, under the optimal solution treatment conditions of 500 °C for 2 h and 540 °C for 4 h, the T-Al9FeNi phase was present in the alloy, and the roundness of primary Si and the aspect ratio of eutectic Si in the alloy reached valley values of 1.46 and 2.56, respectively. With increasing ageing time at 180 °C, the tensile strength significantly improved, while the microhardness first increased and then decreased. When the ageing time was 4 h, microhardness reached a peak value of 155.82 HV. The fracture characteristics changed from quasi-cleavage to the coexistence of quasi-cleavage and dimples. After heat treatment, the high-temperature tensile properties of the alloy improved, which is a significant advantage compared to the as-cast alloy. The stable Al3Ni and Al9FeNi phases inhibited the cracking of the alloy at 350 °C.

To improve the wear resistance of high-strength and high-conductivity Cu–Cr–Zr alloys in high-speed and heavy load friction environments, coatings including Ni–Cu, Ni–Cu-10(W,Si), Ni–Cu–10(Mo,W,Si), and Ni–Cu–15(Mo,W,Si) (with an atomic ratio of Mo,W to Si of 1:2) were prepared using coaxial powder-feeding laser cladding technology. The microstructure and wear performance of coatings were chiefly investigated. The results revealed that (Mo,W)Si2 and MoNiSi phases are found in the Ni–Cu–10(Mo,W,Si) and Ni–Cu–15(Mo,W,Si) coating. WSi2 phases are found in the Ni–Cu–10(W,Si) coating. The degree of grain refinement in Ni–Cu–10(Mo,W,Si) was greater than that of the Ni–Cu–10(W,Si) coating after the effect of Mo. The excellent wear resistance and micro-hardness of the Ni–Cu–15(Mo,W,Si) coating were attributed to the increase in its dispersion phase, which were approximately 34.72 mg/km and 428 HV, 27.1% and 590% higher than the Cu–Cr–Zr substrate, respectively. The existence of silicide plays an important role in grain refinement due to the promotion of nucleation and the inhibition of grain growth. In addition, the wear mechanism transformed from adhesive wear in the Ni–Cu coating with no silicides to abrasive wear in the Ni–Cu–15(Mo,W,Si) coating with high levels of silicides.

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