Simulation of Semi-Solid Casting Process on Cooling Slope Surface

There are many methods to produce ingot with non-dendritic microstructure. Cooling slope method has attracting more attentions because of its simplicity and high process speed. In this method molten metal is poured on tilted slope that is cooled by water circulation underneath. Due to shear stress exerted to the slurry by flowing on the slope, it is solidified with non-dendritic microstructure. By simulation of semi-solid casting with cooling slope, the effects of different pouring conditions on the microstructure of A356 aluminum alloy are investigated. The simulations are carried out by commercial FLOW3D software. The results of simulation tests are compared to experimental results. In the simulations, the time of slurry presence on the slope, solid fraction of the slurry, strain rate and turbulence were investigated. Comparing the results of simulations with experimental results showed that for having the favorable microstructure, with higher sphericity and lower grain size, the time of slurry flowing on the slope must be enough while the shear stress over 60s-1 and turbulence must be as high as possible.