Microstructure and Mechanical Properties of Al-8 pct Si Alloy Prepared by Direct Chill Casting Under Electromagnetic and Ultrasonic Fields

The intermediate frequency electromagnetic field and power ultrasonic field were applied during the direct chill (DC) casting process of Al-8 pct Si alloy. The effects of different physical fields on the solidification microstructure and mechanical properties were studied. The results show that compared to the conventional casting without any treatments, refined microstructures and improved mechanical properties can be obtained when the electromagnetic or ultrasonic field is applied individually. For the case of compound fields, the electromagnetic field can increase the ultrasonic treated region, while the ultrasonic field can enhance the refinement effect of electromagnetic field. Owing to the advantages of both electromagnetic and ultrasonic fields, the microstructure obtained under the compound fields is fine and uniform, leading to a remarkable enhancement of mechanical properties. The interaction mechanism between intermediate frequency electromagnetic field and power ultrasonic field was discussed. The present study may be useful for grain refinement and improvement of mechanical properties of alloys during the DC casting process which is now widely used in industry.