A novel semi-solid slurry-making process was developed, which was a controlled nucleation and growth technique using a specially designed rotational barrel. Experimental study was undertaken to investigate the effects of pouring temperature and rotation speed of barrel on the microstructure of A356 alloy. Localized rapid cooling, combined with vigorous mixing during the initial stage of solidification enhanced wall nucleation and nuclei survival. High nuclei density combined with a much gradual cooling afterwards led to the formation of the near-ideal semi-solid slurry under a large processing window for the pouring temperature. Primary phase presented in mean equivalent diameter of 50-70μm and shape factor of 0.812-0.847, and featured zero-entrapped eutectic.
The semi-solid slurry of wrought aluminum alloy 2024 was prepared by a well developed rheocasting process, low superheat pouring with shearing field(LSPSF). The appreciate combination of pouring temperature and rotation speed of barrel, can give rise to a transition of the growth morphology of primary α(Al) from coarse-dendritic to coarse-particle-like and further to fine-globular. The combined effects of both localized rapid cooling and vigorous mixing during the initial stage of solidification can enhance wall nucleation and nuclei survival, which leads to the formation of fine-globular primary α(Al). By using semi-solid slurry prepared by LSPSF, direct squeeze cast cup-shaped component with improved mechanical properties such as yield strength of 198 MPa, ultimate tensile strength of 306 MPa and elongation of 10.4%, can be obtained.
The microstructure characteristics and mechanical properties of 2024 wrought aluminum alloy produced by a new rheoforming technique under as-cast and optimized heat treatment conditions were investigated. The present rheoforming combined the independently developed rheocasting process, named as LSPSF (low superheat pouring with a shear field) process, and the existing squeeze casting process. The experimental results show that LSPSF can be used to prepare sound semi-solid slurry within 25 s to fully meet the production rate of squeeze casting. The primary α(Al) presents in mean equivalent diameter of 69 μm and shape factor of 0.76, and features zero-entrapped eutectics. Compared with conventional squeeze casting, the present LSPSF rheoforming can improve the microstructures and mechanical properties. An optimized heat treatment results in substantial reduction of microsegregation and significant improvement of mechanical properties, such as yield strength of 321 MPa, ultimate tensile strength of 428 MPa and elongation of 12%.
