Analysis of microstructure evolution and precise solid fraction evaluation of A356 aluminum alloy during partial re-melting by a color etching method

Spheroidization of Al grains is required for the production of semi-solid slurry either by a partial solidification route or partial re-melting route. In this research, A356 aluminum alloy was deformed and partially re-melted to semi-solid state. A segregation sensitive reagent (Weck’s reagent) was used to reveal the inner microstructure of Al grains for the better understanding of the microstructure evolution during partial re-melting. Optical microstructure observation showed that the previously compressed Al dendrites were actually “fractured” during heat treatment and such “fractured” dendrites contributed to the refinement and spheroidization of Al grains. Further study of this phenomenon indicates that the “fractures” are actually migrating high-angle grain boundaries, which was related to the recrystallization that occurred during heat treatment. Moreover, the growth layer of Al grains formed during water quenching is clearly visualized after being etched by Weck’s reagent. Consequently, precise evaluation of solid fractions through image analysis was realized by excluding growth layer when measuring the area of solid phase.