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Effect of Melt Treatment on Microstructure Evolution and Coarsening Mechanism of A356 Al Alloy During Cooling Slope Rheoprocessing

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Abstract

The present study reports the effect of melt treatment, i.e., grain refiner (0.15 wt pct of Al–5Ti–1B) and modifier (0.1 wt pct of Al–10Sr) addition on microstructure formation mechanism of A356 Al alloy, processed at semi-solid state. The semi-solid processing is performed here adopting rheoprocessing route, which involves cooling slope processing and subsequent isothermal holding of the generated slurry. Melt treatment prior to slurry generation shows pronounced effect over the morphology of primary solid (Al) and eutectic Si particles, and to quantify that, shape and size of both the particle types are measured in the present work. Moreover, based on the insight obtained in the present study, possible slurry microstructure formation mechanisms, at the onset of melt treatment, are proposed. Furthermore, mathematical model of primary Al formation and its coarsening is developed within the scope of the present work, based on the experimental findings. Understanding of microstructure formation mechanism as well as the developed mathematical correlations between process variables and slurry morphology are found to be helpful to establish process control during Rheo pressure die casting of the generated slurry, to develop automobile, aviation components.

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Acknowledgments

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 would also like to thank all the members of erstwhile NNMT group, CSIR-CMERI for their cooperation to execute the casting experiments and AFMM, IISc for extending characterization facilities. Finally, the author would like to express his gratitude to Director, IISc for his encouragements.

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

    Prosenjit Das

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Manuscript submitted October 15, 2022; accepted February 26, 2023.

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Das, P. Effect of Melt Treatment on Microstructure Evolution and Coarsening Mechanism of A356 Al Alloy During Cooling Slope Rheoprocessing. Metall Mater Trans B 54, 1383–1407 (2023). https://doi.org/10.1007/s11663-023-02768-7

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