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Effect of casting procedures in the structure and flow behaviour of semisolid A356 alloy

Proni C. T. W., Robert M. H., Zoqui E. J.

Archives of Materials Science and Engineering

2015

Vol. 73, nr 2

82--93

Purpose: Evaluation of different casting methods to produce raw material for thixoforming, aiming costs reduction in the production of thixoformable alloys. Reduction of costs may stimulate the commercial use of the semisolid processing technology (SSM). Design/methodology/approach: It is analysed the effect of different casting routes in the microstructure features in semisolid A356 alloy, and in its rheological behaviour. Different casting procedures were investigated: a) pouring in water cooled Cu mould; b) same as „a)” adding electromagnetic stirring; c) same as „a)” adding mechanical vibration; d) same as „b)” with addition of grain refiner; e) same as „c)” with addition of grain refiner. Cast materials were reheated to the semisolid sate and the effect of different holding times upon the globularization of the primary phase was analysed for each cast structure. The semisolid material in each condition was evaluated concerning rheological behaviour. Mechanical properties of thixoformed products were evaluated using flexion tests. Findings: Despite the several methods currently in use to produce raw material for thixoforming, this work shows that the best combination of quality of thixoformable material/ production cost /process operationality can be achieved using casting in permanent mould, under water cooling and mechanical vibration. Resulting cast material under this condition presents grain size smaller than 100 μm, ideal for SSM. Lower the grain size, lower the primary globule size and higher the roundness of the primary phase particle and lower the apparent viscosity of the semisolid. In the best condition achieved, apparent viscosity measured was circa 105 Pa.s (similar to the working range for glass), leading to a probable homogeneous die filling during thixoforming in high pressure die casting machines (HPDC). Research limitations/implications: Regardless the best microstructure for SSM resulting from casting under mechanical vibration, it is still necessary to reach the optimum casting condition in terms of vibration in order to improve, even more, refinement of the microstructure. Practical implications: The suggested process is a simple technique to reduce costs in the production of raw material for thixoforming. The technology is easily implementable in industries. Originality/value: The development of a simple, original, low cost method to produce raw material for SSM technology.