Skip to main content
SpringerLink
Log in

Primary Phase Morphology of Cooling Slope-Processed A356 Al Alloy and Its Effect on Rheological Properties

  • Technical Paper
  • Published:
International Journal of Metalcasting Aims and scope Submit manuscript

Abstract

A comprehensive study is performed to establish the correlation between microstructural features of the cooling slope-generated slurry (semisolid) of A356 alloy and its non-Newtonian flow behavior, in view of optimizing process variables of rheo-pressure die casting process technology. Differences observed in primary particle’s (α-Al) morphology, i.e., shape, size, and distribution, are originating from cooling slope processing of the alloy with different slope angle and melt treatment (via grain refiner addition) conditions. Isothermal, shear jump, and shear time tests are performed on cooling slope-generated slurry (at 590 °C and at a solid fraction of approx. 0.41) to estimate its rheological properties. Three different shear regimes—low, intermediate, and high shear—are identified from the viscous flow behavior of the slurry at isothermal conditions. Subsequently, a power law model is developed to mathematically express the dependence of slurry viscosity on microstructural features.

Graphical abstract

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16

Similar content being viewed by others

References

  1. D.B. Spencer, R. Mehrabian, M.C. Flemings, Rheological behavior of Sn-15%Pct Pb in the crystallization range. Metall. Trans. 3, 1925–1932 (1972)

    CAS  Google Scholar 

  2. D.H. Kirkwood, Semi-solid metal processing. Int. Mater. Rev. 39, 173–189 (1994)

    CAS  Google Scholar 

  3. G.K. Sigworth, Rheological properties of metal alloys in the semi-solid state. Can. Metall. Q. 35, 101–122 (1996)

    Google Scholar 

  4. A. Megalingam, A.H.B. Ahmad, M.R.B. Maarof, K. Sudhakar, Viscosity measurements in semi-solid metal processing: current status and recent developments. Int. J. Adv. Manufact. Technol. 119, 1435–1459 (2022)

    Google Scholar 

  5. H.V. Atkinson, Modelling the semisolid processing of metallic alloys. Prog. Mater. Sci. 50, 341–412 (2005)

    CAS  Google Scholar 

  6. Z. Fan, Semi-solid metal processing. Int. Mater. Rev. 47, 49–85 (2002)

    CAS  Google Scholar 

  7. R. Canyook, S. Petsut, S. Wisutmethangoon, M.C. Flemings, J. Wannasin, Evolution of microstructure in semi-solid slurries of rheocast aluminum alloy. Trans. Nonferrous Met. Soc. China 20, 1649–1655 (2010)

    CAS  Google Scholar 

  8. R. Canyook, J. Wannasin, S. Wisuthmethangkul, M.C. Flemings, Characterization of the microstructure evolution of a semi-solid metal slurry during the early stages. Acta Mater. 60, 3501–3510 (2012)

    CAS  Google Scholar 

  9. S. Lü, S. Wu, W. Dai, C. Lin, P. An, The indirect ultrasonic vibration process for rheo-squeeze casting of A356 aluminum alloy. J. Mater. Process. Technol. 212, 1281–1287 (2012)

    Google Scholar 

  10. T. Haga, S. Suzuki, Casting of aluminum alloy ingots for thixoforming using a cooling slope. J. Mater. Process. Technol. 118, 169–172 (2001)

    CAS  Google Scholar 

  11. T. Haga, Semisolid strip casting using a twin roll caster equipped with a cooling slope. J. Mater. Process. Technol. 130–131, 558–561 (2002)

    Google Scholar 

  12. Y. Birol, A357 thixoforming feedstock produced by cooling slope casting. J. Mater. Process. Technol. 86, 94–101 (2007)

    Google Scholar 

  13. Y. Birol, Cooling slope casting and thixoforming of hypereutectic A390 alloy. J. Mater. Process. Technol. 207, 200–203 (2008)

    CAS  Google Scholar 

  14. Y. Birol, Semi-solid processing of the primary aluminum die casting alloy A365. J. Alloy. Compd. 473(1–2), 133–138 (2009)

    CAS  Google Scholar 

  15. Q.D. Qin, Y.G. Zhao, P.J. Cong, W. Zhou, B. Xu, Semisolid microstructure of Mg2Si/Al composite by cooling slope cast and its evolution during partial remelting process. Mater. Sci. Eng., A 444(1–2), 99–103 (2007)

    Google Scholar 

  16. S. Gencalp, N. Saklakoglu, Semisolid microstructure evolution during cooling slope casting under vibration of A380 aluminum alloy. Mater. Manuf. Processes 25, 943–947 (2010)

    CAS  Google Scholar 

  17. M.M. Shehata, S. El-Hadad, M.E. Moussa, et al., Optimizing the pouring temperature for semisolid casting of a hypereutectic Al–Si alloy using the cooling slope plate method. Inter. Metalcast. 15, 488–499 (2021). https://doi.org/10.1007/s40962-020-00465-8

    Article  CAS  Google Scholar 

  18. M.M. Shehata, S. El-Hadad, M.E. Moussa, et al., The combined effect of cooling slope plate casting and mold vibration on microstructure, hardness and wear behavior of Al–Si alloy (A390). Inter. Metalcast. 15, 763–779 (2021). https://doi.org/10.1007/s40962-020-00497-0

    Article  CAS  Google Scholar 

  19. M.A. Abdelgnei, M.Z. Omar, M.J. Ghazali, M.N. Mohammed, Microstructure evaluation and mechanical properties of thixoformed Al–5.7Si–2Cu–0.3Mg aluminum alloys. Inter. Metalcast. 16, 370–384 (2022). https://doi.org/10.1007/s40962-021-00610-x

    Article  CAS  Google Scholar 

  20. S. Acar, K.A. Guler, A thorough study on thixoformability of the cooling slope cast 7075 Feedstocks: step-by-step optimization of the feedstock production and thixoforming processes. Inter. Matalcast. (2022). https://doi.org/10.1007/s40962-022-00801-0

    Article  Google Scholar 

  21. A.K. Yadav, V. Kumar, M.S. Ankit, Microstructure and mechanical properties of an in-situ Al 356–Mg2Si-Tib2 hybrid composite prepared by stir and cooling slope Casting. Inter. Matalcast. (2022). https://doi.org/10.1007/s40962-022-00804-x

    Article  Google Scholar 

  22. Z. Zhang, T. Chen, H. Xue, G. Bi, Y. Ma, Microstructure evolution of an al-si alloy during shear-vibration coupling sub-rapid solidification and the effects of processing parameters. Inter. Metalcast. (2022). https://doi.org/10.1007/s40962-022-00809-6

    Article  Google Scholar 

  23. E.C. Legoretta, H.V. Atkinson, H. Jones, Cooling slope casting to obtain thixotropic feedstock II: observations with A356 alloy. J. Mater. Sci. 43, 5456–5469 (2008)

    CAS  Google Scholar 

  24. F. Taghavi, A. Ghassemi, Study on the effects of the length and angle of inclined plate on the thixotropic microstructure of A356 aluminum alloy. Mater. Des. 30, 1762–1767 (2009)

    CAS  Google Scholar 

  25. N.K. Kund, Effect of tilted plate vibration on solidification and microstructural and mechanical properties of semisolid cast and heat-treated A356Al alloy. Int. J. Adv. Manuf. Technol. 97, 1617–1626 (2018)

    Google Scholar 

  26. R. Guan, L. Zhang, C. Wang, J. Wen, J. Cui, Three-dimensional analysis of the modified sloping cooling/shearing process. J. Univ. Sci. Technol. Beijing 14(2), 146–150 (2007)

    CAS  Google Scholar 

  27. T. Wang, B. Pustal, M. Abondano, T. Grimmig, A. Bührig-Polaczek, M. Wu, A. Ludwig, Simulation of cooling channel rheocasting process of A356 aluminum alloy using a three-phase volume averaging model. Trans. Nonferrous Met. Soc. China 15(2), 1–6 (2005)

    CAS  Google Scholar 

  28. P. Das, S.K. Samanta, H. Chattopadhyay, P. Dutta, Effect of pouring temperature on cooling slope casting of semi-solid Al–Si–Mg alloy. Acta Metall. Sin. (English Lett.) 25, 329–339 (2012)

    CAS  Google Scholar 

  29. P. Das, S.K. Samanta, H. Chattopadhyay, B.B. Sharma, P. Dutta, Eulerian two-phase flow simulation and experimental validation of semisolid slurry generation process using cooling slope. Mater. Sci. Technol. 29, 83–92 (2013)

    CAS  Google Scholar 

  30. P. Das, S.K. Samanta, B. Mondal, P. Dutta, Multiphase model of semisolid slurry generation and isothermal holding during cooling slope rheoprocessing of A356 Al alloy. Metall. Mater. Trans. B 49, 1925–1944 (2018)

    CAS  Google Scholar 

  31. P. Das, S.K. Samanta, H. Chattopadhyay, P. Dutta, B.R.K. Venkatapathi, Microstructural evolution of A356 Al alloy during flow along a cooling slope. Trans. Indian Inst. Met. 65(6), 669–672 (2012)

    CAS  Google Scholar 

  32. P. Das, S. Dutta, S.K. Samanta, Evaluation of primary phase morphology of cooling slope cast Al-Si-Mg alloy samples using image texture analysis. Proc. Inst. Mech. Eng. Part B J. Eng. Manuf. 227, 1474 (2013)

    CAS  Google Scholar 

  33. J. Mewis, N.J. Wagner, Thixotropy a general review. J. Non-Newton. Fluid Mech. 147–148, 214–227 (2009)

    Google Scholar 

  34. J. Mewis, N.J. Wagner, Thixotropy. Adv. Coll. Interface. Sci. 147–148, 214–227 (2009)

    Google Scholar 

  35. H.A. Barnes, Thixotropy—a review. J. Non-Newton. Fluid Mech. 70, 1–33 (1997)

    CAS  Google Scholar 

  36. E.J. Zoqui, M. Paes, M.H. Robert, Effect of macrostructure and microstructure on the viscosity of the A356 alloy in the semi-solid state. J. Mater. Process. Technol. 153–154, 300–306 (2004)

    Google Scholar 

  37. M. Paes, E.J. Zoqui, Semi-solid behavior of new Al–Si–Mg alloys for thixoforming. Mater. Sci. Eng. A 406, 63–73 (2005)

    Google Scholar 

  38. E.A. Vieira, A.M. Kliauga, M. Ferrante, Microstructural evolution and rheological behavior of aluminum alloys A356, and A356 + 0.5% Sn designed for thixocasting. J. Mater. Process. Technol. 155–156, 1623–1628 (2004)

    Google Scholar 

  39. O. Lashkari, F. Ajersch, A. Charette, X. Chen, Microstructure and rheological behavior of hypereutectic semi-solid Al-Si alloy under low shear rates compression test. Mater. Sci. Eng. A 492, 377–382 (2008)

    Google Scholar 

  40. O. Bustos, S. Ordoñez, Rheological and microstructural study of A356 alloy solidified under magnetic stirring. Int. J. Metalcast. 7, 29–37 (2013)

    CAS  Google Scholar 

  41. Y. Zhu, J. Tang, Y. Xiong, Z. Wu, C. Wang, D. Zeng, The influences of the microstructure morphology of A356 alloy on its rheological behavior in the semi-solid state. Sci. Technol. Adv. Mater. 2, 219–223 (2001)

    CAS  Google Scholar 

  42. S. Nafisi, O. Lashkari, R. Ghomashchi, F. Ajersch, A. Charette, Microstructure and rheological behavior of grain refined and modified semi-solid A356 Al–Si slurries. Acta Mater. 54, 3503–3511 (2006)

    CAS  Google Scholar 

  43. O. Lashkari, R. Ghomashchi, The implication of rheology in semi-solid metal processes: an overview. J. Mater. Process. Technol. 182, 229–240 (2007)

    CAS  Google Scholar 

  44. O. Lashkari, R. Ghomashchi, The implication of rheological principles for characterization of semi-solid Al–Si cast billets. J. Mater. Sci. 41, 5958–5965 (2006)

    CAS  Google Scholar 

  45. O. Lashkari, R. Ghomashchi, Deformation behavior of semi-solid A356 Al–Si alloy at low shear rates: effect of morphology. Mater. Sci. Eng. A 454–455, 30–36 (2007)

    Google Scholar 

  46. O. Lashkari, R. Ghomashchi, A new machine to characterize microstructural evolution of semi-solid metal billets through viscometery. Mater. Des. 28, 1321–1325 (2007)

    CAS  Google Scholar 

  47. N. Barman, P. Dutta, Rheology of A356 alloy during solidification under stirring. Trans. Indian Inst. Met. 67(1), 101–104 (2014)

    CAS  Google Scholar 

  48. P. Das, S.K. Samanta, H. Chattopadhyay, P. Dutta, N. Barman, Rheological characterization of semi-solid A356 aluminum alloy. Solid State Phenom. 192–193, 329–334 (2013)

    Google Scholar 

  49. P. Das, S.K. Samanta, P. Dutta, Rheological behavior of Al–7Si–0.3Mg alloy at mushy state. Metall. Mater. Trans. B. 46, 1302–1313 (2015)

    CAS  Google Scholar 

  50. P. Das, B. Bhuniya, S.K. Samanta, P. Dutta, Studies on die filling of A356 Al alloy and development of a steering knuckle component using rheo pressure die casting system. J. Mater. Process. Technol. 271, 293–311 (2019)

    CAS  Google Scholar 

  51. P. Das, S.K. Samanta, S. Bera, P. Dutta, Microstructure evolution and rheological behavior of cooling slope processed Al–Si–Cu–Fe alloy slurry. Metall. Mater. Trans. A. 47, 2243–2256 (2016)

    CAS  Google Scholar 

  52. S. Ren, F. Wang, J. Sun, Z. Liu, P. Mao, Gating system design based on numerical simulation and production experiment verification of aluminum alloy bracket fabricated by semi-solid Rheo-die casting process. Int. J. Metalcast. 16(2), 878–893 (2022)

    Google Scholar 

  53. S. Kumar, P. Das, S.K. Tiwari, M.K. Mondal, S. Bera, S.K. Roy, Study of microstructure evolution during semi-solid processing of an in-situ Al alloy composite. Mater. Manuf. Processes 30, 356–366 (2015)

    CAS  Google Scholar 

  54. D. Brabazon, D.J. Browne, A.J. Carr, Experimental investigation of the transient and steady state rheological behavior of Al–Si alloys in the mushy state. Mater. Sci. Eng. A 356, 69–80 (2003)

    Google Scholar 

  55. H. Chen, J. Chen, J. Liao, The influence of shearing conditions on the rheology of semi-solid magnesium alloy. Mater. Sci. Eng. A 487, 114–119 (2008)

    Google Scholar 

  56. P. Das, S.K. Samanta, R. Das, P. Dutta, Optimization of degree of sphericity of primary phase during cooling slope casting of A356 Al alloy: Taguchi method and regression analysis. Measurement 55, 605–615 (2014)

    Google Scholar 

  57. P. Das, Effect of process variables and melt treatment conditions during cooling slope semi solid slurry generation process of Al–7Si–0.3 Mg alloy. Mater. Today Commun. 33, 104944 (2022)

    CAS  Google Scholar 

  58. P. Das, P. Dutta, Globularization of Primary phase of Al–7Si–0.3Mg alloy during cooling slope processing and isothermal holding. Trans. Indian Inst. Met. 74, 1241–1251 (2021)

    CAS  Google Scholar 

  59. P. Das, Microstructure evolution during Rheoprocessing of A356 Al alloy using cooling slope. Inter. Metalcast. (2022). https://doi.org/10.1007/s40962-022-00908-4

    Article  Google Scholar 

  60. S. Oka, Principles of Rheometry, in Rheology, Theory and Applications. ed. by F.R. Eirich (Academic Press, New York, 1960), pp.17–82

    Google Scholar 

  61. P. Das, S.K. Samanta, H. Chattopadhyay, P. Dutta, Studies on rheocasting using cooling slope. Solid State Phenom. 192–193, 341–346 (2013)

    Google Scholar 

  62. A. Blanco, Z. Azpilgain, J. Lozares, P. Kapranos, I. Hurtado, Rheological characterization of A201 aluminum alloy. Trans. Nonferrous Met. Soc. China 20, 1638–1642 (2010)

    CAS  Google Scholar 

  63. M. Modigell, J. Koke, Rheological modelling on semi-solid metal alloys and simulation of thixocasting processes. J. Mater. Process. Technol. 111, 53–58 (2001)

    CAS  Google Scholar 

  64. J. Koke, M. Modigell, Flow behavior of semi-solid metal alloys. J. Non Newton. Fluid Mech. 112, 141–160 (2003)

    CAS  Google Scholar 

Download references

Acknowledgements

The author would like to thank SERB, DST, Government of India, and CSIR, Government of India, for their financial support to this work vide grant no. SB/EMEQ-449/2014 and OLP121212, respectively. The author also like to thank Director, IISc, for his continuous encouragement and all the members of erstwhile NNMT group, CSIR-CMERI, for their cooperation and cordial help toward successful completion of this research work.

Author information

Authors and Affiliations

  1. Advanced Manufacturing and Materials Processing Laboratory, Department of Materials Engineering, Indian Institute of Science Bangalore, Bengaluru, 560012, India

    Prosenjit Das

Authors
  1. Prosenjit Das
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Prosenjit Das.

Ethics declarations

Conflict of interest

The author declares that there is no conflict of interest.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Das, P. Primary Phase Morphology of Cooling Slope-Processed A356 Al Alloy and Its Effect on Rheological Properties. Inter Metalcast 17, 2184–2206 (2023). https://doi.org/10.1007/s40962-022-00930-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40962-022-00930-6

Keywords

Search

Navigation