In-situ microstructural control of A6082 alloy to modify second phase particles by melt conditioned direct chill (MC-DC) casting process - A novel approach

Abstract Controlling the formation of noncompact second phase particles during direct chill (DC) casting of aluminium alloys with grain refiner addition remains challenging, as it results in energy intensive homogenisation and deformation problems. In this work, we employed a novel strategy in the DC casting of A6082 alloy to produce billets with a fine-scale dispersion of second phase particles. The strategy involves maintaining 2 to 7 °C above alloy liquidus as a thermal condition in the sump by in-situ melt conditioning (MC) using a rotor-stator high-shear device operated at a critical rotation speed. As a result, in-situ control of solidification behaviour is achieved to precisely tailor the as-cast microstructure. The billet grain refinement is attained by MC-DC casting without the deliberate addition of chemical grain refiners. The microstructure of the MC-DC cast billet at the critical rotation speed showed a fine-scale dendritic structure with refined secondary dendrite arm spacing (SDAS). The solidification front proceeded with a shallow sump and a corresponding shorter solidification time, higher cooling rate, higher temperature gradient, and smooth solidification rate profile. The ideal fine-scale dendrites with low SDAS divided the remaining eutectic liquid into fine-scale and isolated liquid pockets, resulting in fine-scale, compact morphology, and uniform distribution of second phase particles in the as-cast microstructure. The MC-DC casting process showed the ability to increase the cast house production rate by increasing the casting speed without bleeding the billet. The present approach could be beneficial for eliminating or reducing the homogenisation practice and may also introduce significant flexibility in using recycled Al alloys in the industry.