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Migration of crystals during the filling of semi-solid castings

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Abstract

In cold-chamber high-pressure die castings (HPDC), the microstructure consists of coarse externally solidified crystals (ESCs) that are commonly observed in the central region of cross sections. In the present work, controlled laboratory scale casting experiments have been conducted with particular emphasis on the flow and solidification conditions. An A356 aluminum alloy was used to produce castings by pouring semi-solid metal through a steel die. Microstructures similar to those encountered in HPDC have been produced and the resulting microstructure is found to depend on the melt and die temperature: (1) the fraction of ESCs determines the extent of migration to the central region; (2) a maximum packing determines the area fraction of ESCs in the center; and (3) the die temperature affects the position of the ESCs—a higher die temperature can induce a displaced ESC distribution. It is found that the migration of crystals to the central region requires a flow, which is constrained at all melt/die interfaces. Furthermore, potential lift mechanisms are discussed. An assessment of the Saffman lift force on individual particles shows it has no significant effect on the migration of ESCs.

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Author notes

  1. H. I. Laukli (Research Scientist)

    Present address: the Department of Materials Technology, NTNU, N-7491, Trondheim, Norway

Authors and Affiliations

  1. Hydro Aluminium RDM, N-6601, Sunndalsøra, Norway

    H. I. Laukli (Research Scientist)

  2. the CRC for Cast Metals Manufacturing, Division of Materials Engineering, The University of Queensland, 4072, Brisbane, QLD, Australia

    C. M. Gourlay (Postgraduate Student) & A. K. Dahle (Associate Professor)

Authors
  1. H. I. Laukli
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  2. C. M. Gourlay
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  3. A. K. Dahle
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Laukli, H.I., Gourlay, C.M. & Dahle, A.K. Migration of crystals during the filling of semi-solid castings. Metall Mater Trans A 36, 805–818 (2005). https://doi.org/10.1007/s11661-005-0195-z

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  • DOI: https://doi.org/10.1007/s11661-005-0195-z

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