Microstructure and Porosity Behavior of Spray Formed Al Alloy Processed by Cold Rolling Rashmi Mittal, Prabh Simranjit Singh, Rajeev Sehrawat, Deepak Kr Tyagi, Milan Kr Bera, and Anil Sharma Abstract An efficient spray forming technique was utilized to cast Pb-added Al-Si alloys. It was then rolled to a different percentages (0–80%) using rolling machine and microstructural characteristics as well as porosity behavior of casting alloy were systematically studied. It is noteworthy that the distribution of Pb was nearly uniform all through the aluminum phase and it was mainly at the grain boundary. Also, the grains of aluminum were found to be elongated along the rolling direction after 80% rolling. Porosity was minimum at peripheral region of the deposit and it decreased as rolling percentage is increased. Keywords Al alloy · Spray deposition · Rolling · Microstructure · Porosity 1 Introduction The excellent features of aluminum–silicon (Al-Si) alloys, for instance, low density, lightweight, high strength, low corrosion rate, better tribological properties and above all cost-effectiveness of Al-Si alloys have driven its wide utilization in various engi- neering applications. The conventional method of casting leads to coarse silicon R. Mittal (B ) · P. S. Singh · R. Sehrawat · D. K. Tyagi · M. K. Bera · A. Sharma Department of Physics, Maharishi Markandeshwar (Deemed to be University), Mullana 133207, India e-mail: rashmimittal3@gmail.com P. S. Singh e-mail: ashmansidhu@gmail.com R. Sehrawat e-mail: rajeev.sehrawat@gmail.com D. K. Tyagi e-mail: deepak.tyagi76@gmail.com M. K. Bera e-mail: m.k.bera.iitkgp@gmail.com A. Sharma e-mail: anil67042@gmail.com © The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2021 B. P. Sharma et al. (eds.), Advances in Engineering Materials, Lecture Notes in Mechanical Engineering, https://doi.org/10.1007/978-981-33-6029-7_48 515