Preparation and Rheocasting of Semi-solid Aluminum-alloy Slurry with Indirect Ultrasonic Vibration Process

Abstract

ABSTRACTDirect ultrasonic vibration (DUV) method by dipping the horn into the melt can be used to make semi-solid metal slurry, but application of this process is embarrassed because of the erosion problem of titanium-alloy horn by aluminum melt. In order to avoid this problem, a slurry-making process with indirect ultrasonic vibration (IUV), in which the horn is vibrated under the outside of the metallic cup containing alloy melt, has been developed in this research. Semisolid slurry of A356 Al alloy was prepared by this process, and the effects of IUV treatment time on the morphology of the primary α-Al phase and mechanical properties of rheo-diecasting samples were studied. The results indicate that excellent semisolid slurry of A356 Al alloy could be obtained within 50s by applying IUV near its liquidus temperature, and the average diameter and shape coefficient of the primary α-Al particles were 75μm and 0.62, respectively. IUV treatment time had a significant effect on the mechanical properties of the rheo-diecasting samples, and samples treated by IUV for 50s had the maximum tensile strength and elongation. The maximum as-cast tensile strength and elongation were 244MPa and 7.5% respectively, which were increased by 10% and 75% respectively compared to conventional molten-melt die-casting samples. In addition, the mechanism of preparing semisolid slurry of A356 Al alloy by IUV is discussed.