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An Al-Si-P master alloy has been developed by an in-situ reaction and the electron probe microanalyzer (EPMA) results show that there are many pre-formed AlP particles contained in the master alloy. Silicon introduced into the system plays an important role in remarkably improving the distribution and content of AlP particles due to their similar crystal structure and lattice parameters. ZL109 alloys have shown fast modification response to the addition of 0.5% Al-15Si-3.5P master alloy at 720°C, with a mass of primary Si precipitating in size of about 15 μm. Also, coarse primary Si grains in Al-30Si alloy can be refined dramatically from 150 μm to 37 μm after the addition of 2.0% Al-15Si-3.5P master alloy at 850°C. The P recovery of the Al-15Si-3.5P master alloy is much higher than that of a Cu-8.5P master alloy due to the pre-formed AlP particles.

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