Characterization of heat treatment-driven microstructural evolution, mechanical properties and electrochemical behavior of direct powder forged Al–10Si–0.3Mg alloy

• Direct aging at 200°C for 360 min (DA-2) offers the best overall balance of mechanical strength (~203 MPa), ductility (~4.4%), and corrosion resistance for direct powder forged Al–10Si–0.3Mg. • T6 treatment (solutionizing at 500°C for 180 min + aging at 200°C for 360 min) achieves the highest tensile strength (207.15 MPa) and elongation (5.02%), but with slightly inferior electrochemical performance compared to DA-2. • Solution treatment alone leads to partial Si dissolution, increased porosity, and the lowest corrosion resistance, demonstrating the necessity of subsequent aging. • DPF combined with optimized heat treatment enhances Si particle distribution uniformity and reduces interparticle boundaries, critical for aerospace and automotive applications.