Mechanical stir casting of aluminium alloys from the mushy state: process, microstructure and mechanical properties

A comprehensive study was carried out to establish the effects of controlled stirring during solidification on the microstructure and mechanical properties of aluminium alloys, in comparison to conventionally gravity chill cast material. A novel device comprising a grooved reaction bonded silicon nitride rod rotating in a tube-like crucible was used to process aluminium alloys in the mushy state. The stir casting device was specially designed to also enable rheometric study of the alloys in this condition. A factorial design of experiments was used to determine the effect of the process variables shear rate (γ̇), shear time (ts), and volume fraction solid during shear (fs) on microstructure and both static and dynamic mechanical properties of the stir cast alloy. Investigation of the microstructure consisted of computer-aided image analysis of the primary phase morphology. A more globular primary phase was achieved at low values of fs, but this was not the optimum morphology for mechanical properties. In all cases, improved mechanical properties and reduced porosity were obtained in the stir cast condition in comparison with conventional casting and in comparison with previous work on stir casting. Comparison with alloy commercially rheocast via electromagnetic stirring, however, showed that the latter had superior mechanical properties. It is proposed that the mechanical stir casting process be considered as an alternative to gravity die casting in cases where very simple and thick walled shapes are required.