Fe-intermetallic compounds are commonly detrimental for mechanical properties and formability of aluminum alloys. In this study, the refinement of Fe-intermetallic compounds and mechanical properties in high Fe-containing AlMgSi alloys were studied by caliber rolling. The Al(2.22.3) mass%Si0.9 mass%Mg(1, 1.5 and 2) mass%Fe alloys were severely deformed by the multi-pass caliber rolling at 573 and 723 K. Fe-intermetallic compounds were finely fragmented with the smallest size of around 200 nm. The morphologies of fragmented Fe compounds in the Al matrix depend on the as-cast microstructure and deformation behavior with better distribution in the outer area than in the center area. Good ultimate strength of 345360 MPa and high elongation of 1525% were achieved after 95% caliber rolling.
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