*Article* **Microstructure Comparison for AlSn20Cu Antifriction Alloys Prepared by Semi-Continuous Casting, Semi-Solid Die Casting, and Spray Forming**

**Shuhui Huang 1,2, Baohong Zhu 1,2,\*, Yongan Zhang 1,2, Hongwei Liu 1,2, Shuaishuai Wu 1,2 and Haofeng Xie 1,2**


**Abstract:** Antifriction alloys such as AlSn20Cu are key material options for sliding bearings used in machinery. Uniform distribution and a near-equiaxed granularity tin phase are generally considered to be ideal characteristics of an AlSn20Cu antifriction alloy, although these properties vary by fabrication method. In this study, to analyze the variation of the microstructure with the fabrication method, AlSn20Cu alloys are prepared by three methods: semi-continuous casting, semi-solid die casting, and spray forming. Bearing blanks are subsequently prepared from the fabricated alloys using different processes. Morphological information, such as the total area ratio and average particle diameter of the tin phase, are quantitatively characterized. For the tin phase of the AlSn20Cu alloy, the deformation and annealing involved in semi-continuous casting leads to a prolate particle shape. The average particle diameter of the tin phase is 12.6 μm, and the overall distribution state is related to the deformation direction. The tin phase of AlSn20Cu alloys prepared by semi-solid die casting presents both nearly spherical and strip shapes, with an average particle diameter of 9.6 μm. The tin phase of AlSn20Cu alloys prepared by spray forming and blocking hot extrusion presents a nearly equilateral shape, with an average particle diameter of 6.2 μm. These results indicate that, of the three preparation methods analyzed in this study, semi-solid die casting provides the shortest process flow time, whereas a finer and more uniform tin-phase structure may be obtained using the spray-forming process. The semi-solid die casting method presents the greatest potential for industrial application, and this method therefore presents a promising possibility for further optimization.

**Keywords:** AlSn20Cu alloy; microstructure; semi-continuous casting; semi-solid die casting; spray forming; antifriction alloys; bearings
