Analysis of the Effect of Simultaneous Melt Shearing and Cooling on Grain Formation and Rheology of A356 Aluminum Alloy

Despite the dozens of earlier research verifications, the contribution of shearing of molten metallic alloys during their solidification to grain formation is still ambiguous. Also, modeling of this phenomenon has received very little attention. Experiments were conducted in this study to investigate the effect of the shear rate on the density, size, and shape factor of the formed grains up to a solid fraction of 0.15 for the solidifying A356 aluminum alloy in the coaxial cylinder viscometer. The rheology of the formed semisolid slurry was studied as well. Results exhibited morphological evolution and grain refinement. The grain number density increased from 5 x 108 m-3 in the absence of melt shearing to reach 4 x 109 m-3 at the shear rate of 250 s-1. Also, the shape factor was improved to reach 0.78. Based on the experimental investigations, the grain number density under shearing was correlated to the shear rate and the grain number density in the absence of shearing via an empirical formula. A shear-dependent grain multiplication factor was deduced. The alloy exhibited a shear-thinning behavior where the viscosity obeyed the power law with a constant and an exponent of 0.9264 and 0.468, respectively. Moreover, the measured data were fitted to several proposed viscosity models and the model of Hirai et al. showed the best fit; therefore, it was recommended for predicting the viscosity of semisolid slurries.