Elaboration of metal matrix composites from thixotropic alloy slurries using a new magnetohydrodynamic caster

Abstract

The working principle and the peculiarities of a new electromagnetic rheocaster, which is based on the use of rotating permanent magnets and which allows the production of intense three-dimensional (3-D) multiphase flows in solidifying semisolid alloy slurries and metal matrix composites, are described. This process can be applied to the direct continuous casting of billets, tubes, and slabs and is characterized by very low electric power consumption. Local measurement techniques are applied to the study of the evolution of non-Newtonian magnetohydrodynamic multiphase flow phenomena with the rotational speed of the inductor, the solid fraction of the aluminum alloy matrix, and the size and volume percent of SiC particles. An order of magnitude analysis of the various forces acting on the suspended crystals and SiC particles is given. The Theological behavior of electromagnetically rheocast ferrous metals, simulated by a lead-tin alloy, is also investigated. Satisfactory results concerning the microstructure of solidified aluminum slurries and aluminum matrix composites (homogeneity, crystal shape, grain size, fraction of primary solid, and distribution of SiC particles) were obtained. A discussion is presented relating the metallurgical findings to the heat and three-phase flow measurements.