Effects of electromagnetic directional solidification conditions on the separation of primary silicon from Al-Si alloy with high Si content

Abstract In the present work, a continuous growth model of primary silicon from Al-Si melts was established based on the experimental and numerical data to analyze the separation mechanism of primary silicon from Al-Si alloy with high silicon content during electromagnetic directional solidification process. Results show that the separation of primary Si from Al-Si melts depends on the growth rate of primary Si phase and the solidification rate of the melts. Moreover, the separation and enrichment effects of primary Si during the electromagnetic directional solidification process could be improved by enhancing the bottom cooling conditions of crucible and the stirring strength of Al-Si alloy melts. Finally, the distribution and composition of phases and microstructures of the Al-Si alloy after the electromagnetic directional solidification technique were also analyzed and discussed.