The effect of the complex ligature with nickel and REM (Ce, La) aluminides on the structure formation, the nature of the distribution of the elements, and the microhardness of the structural constituents of Al-5 wt.% Cu aluminum alloy were investigated. On the example of microalloying of the Al-5 wt.% Cu alloy with a master alloy containing Ni and REM (Ce, La) aluminides it was shown that a redistribution of Al and Cu occurs in α-solid solution and eutectic. This is reflected in the refinement of α-solid solution and eutectic at 0.15 wt.% of the master alloy addition and, accordingly, increases the microhardness of α-solid solution by 100 MPa and eutectic by 125 MPa.

Understanding the influence of iron impurity on the formation of the structure and the properties of hypereutectic aluminum-silicon alloys are important for achieving the required quality of castings, especially those obtained from secondary materials. In the present work, the influence of different iron contents (0.3, 1.1, and 2.0 wt.%) on the crystallization process, microstructure and mechanical properties of the Al-15% Si alloy was studied. It is shown that the presence of iron impurity in the Al-15% Si alloy leads to increasing the eutectic crystallization time from 6.2 to 7.6 s at increasing the iron content from 0.3 wt.% to 1.1 wt.%, changing the structure of the alloy eutectic in the solid state. The primary silicon and β-Al5SiFe phase coexist in the structure of the Al-15% Si alloys at a temperature below 575 °C in the range of iron concentrations from 0 to 2 wt.% in equilibrium conditions. In the experimental alloys structure, the primary crystals of the β-phase were metallographically detected only in the alloys containing 1.1 and 2 wt.% of iron impurity. Increase of the iron content up to 2 wt.% significantly reduces the mechanical properties of the Al-15% Si alloy due to the formation of large platelet-like inclusions of β-Al5SiFe phase.

Analysis of the use of the Russian materials (liquid glass and softening additives) has been made in accordance with the modern requirements for use in the technological processes of casting as binding materials in the production of large-sized steel railway casting. The reasons for poor knockout of liquid glass mixtures have been investigated. A complex action softening additive has been recommended for a better knocking-out ability. This solution provides a softening effect at the points of maximum formation of the liquid glass matrix strength in the processes of polymorphic transformation of the material under the influence of elevated temperatures as the result of filling the mold cavity by the melt. It has been shown that the use of additives of complex action leads to the decrease in the specific work of the knockout by four – seven times depending on the composition of the mixture and the design features of the casting. Experimental-industrial tests of the proposed method for softening the liquid glass mixtures have been made and the "Front Buffer Stop" casting has been made (for the rolling stock of locomotives and railway wagons). The tests confirmed the effectiveness and expediency of implementation of new liquid glass mixtures with softening additives in conditions of foundry enterprises.