Influence of Al-alloy composition on the potential of forced convection to reduce grain size and prevent macrosegregation

In addition to alloy composition, the grain size and a homogeneous phase distribution plays a major role to adjust the properties of cast and wrought aluminium alloys. To achieve grain refinement in solidification processes several methods are common: add-on of grain refiners, rapid cooling conditions, mechanical or electromagnetic stirring, or ultrasonic treatment.
The generation of an additional forced flow in the melt offers the possibility to control the grain size without chemical additives.
AC magnetic fields permit a contactless method to generate such forced flow in the liquid metal. Even more: It is possible to control the flow inside the bulk and tune the grain size of the solidified metal. Many studies have shown the complex interaction of magnetic field and melt flow and between melt flow and solidification structure. Therefore, a profound understanding of the mechanisms and well-justified flow structures in space and time are necessary to produce superior casting structures.
In this presentation experimental results are shown to understand the impact of alloy composition on the grain size and phase distribution for different flow conditions. To typify different solidification behaviors we compare various compositions. For this study pure aluminium, wrought aluminium alloy and an AlSi7-alloy was used. Our results demonstrate the restriction of meaningful implementation in low-alloy and the potential to control the grain size in wrought and cast alloys.