Abstract
Preparation of metallic semisolid slurries using the cooling slope method is increasingly becoming popular because of the simplicity of design and control of the process. Microstructural features of the resultant semisolid castings such as size and sphericity of the primary particles are affected by several processing parameters such as pouring rate, cooling slope surface angle and length as well as the melt superheat. In this work, a miniature cooling slope for semisolid casting of small parts was built and attempts were made to develop an empirical relationship showing the correlation between the sphericity of the microstructure of semisolid cast 6061-aluminum alloy and the processing variables. The relationships were developed by a two-level factorial method. The results showed that the interaction of cooling slope length and pouring rate factors had the most effect on the sphericity of the final semisolid cast microstructure.
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