Applications of Al–Ni alloys are limited because their matrix is weaker than other binary aluminium alloys. Ultrasonic treatment (UST) is an effective tool for grain refinement that can strengthen the matrix phase. It not only reduces the grain size and porosity but also refines and uniformly distributes the secondary phase, which can influence the mechanical properties of Al–Ni alloys. Varying the amount of nickel (1, 2, 3, and 5 wt-%) in molten aluminium along with ultrasonication of the melt is investigated through grain-structure, mechanical properties, and fractography. Mechanical properties of the alloys subjected to UST are superior to respective as-cast alloys. UST also altered the fracture behaviour from dominant ductile fracture in as-cast alloys to dominant mixed mode fracture.
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