Improved degassing efficiency and mechanical properties of A356 aluminium alloy castings by high shear melt conditioning (HSMC) technology

Abstract The degassing of aluminium alloy melts is a crucial step in the production of high-quality casting products, as the presence of dissolved hydrogen and oxide bi-films is detrimental to the mechanical properties. Current rotary degassing techniques are effective, but they lack efficiency because of the high gas flow and long processing times required. This study aims to solve this problem by presenting an innovative rotor-stator degassing technology, that combines controlled inert gas injection with intensive melt shearing. It has been applied to the liquid metal treatment of an aluminium cast alloy to evaluate the effect on melt cleanliness, casting integrity and mechanical properties. The optimum conditions for an efficient bubble dispersion have been obtained by water modelling. The melt quality during and after degassing has been assessed by in-situ measurement of hydrogen concentration and by reduced pressure test sampling for oxide bi-films and porosity content evaluation. This new technology is faster, requires less gas flow consumption and produces higher melt quality than the existing degassing techniques, due to a characteristic combination of distributive and dispersive mixing flow. In addition, re-gassing is minimised, maintaining a high melt quality for longer time after processing. This results in castings with less defects and better mechanical properties. The improved degassing efficiency of this technology makes it an excellent alternative in industry to increase melt quality and casting productivity.