• Mg/Si alloying combined with T6 treatment significantly enhances the strength of cast Al-2.3Fe alloy while maintaining high electrical conductivity, achieving a UTS of 309.5 MPa and EC of 52.5% IACS.
• Optimizing the Mg/Si ratio to 0.56 balances solid solubility and precipitation, minimizing conductivity loss and maximizing mechanical properties.
• The addition of Mg and Si alters the solidification path, refining second-phase morphology and phase constitution, which improves aging response.
• The developed Al-2.3Fe-Mg-Si alloy offers a promising alternative to Cu conductors for automotive motor rotors, meeting the demanding requirements of high strength and conductivity.