Evolution of globular microstructure in new rheocasting and super rheocasting semi-solid slurries

Based on the solidification theory for metal alloys, a simple recipe for the controlled processing of globular microstructures without external stirring is presented: Firstly, small solidification nuclei must be distributed homogeneously throughout a melt. In New Rheocasting (NRC) these nuclei are formed by forced homogeneous nucleation due to partial quenching of the melt, while in Super Rheocasting (SRC) the nuclei are second phase particles in specially designed alloys, which are grown in a controlled fashion in a certain temperature range. Potential alloy compositions for SRC are provided. Secondly, given these melts with small particles in them, globular growth can be assured by utilizing the Gibbs-Thomson self healing effect and slow further cooling to allow diffusion in the melt and to suppress constitutional supercooling. This simple recipe is applicable to various ferrous and non-ferrous alloys. If an SRC alloy is cooled more rapidly than necessary for globular growth of the primary phase, but is held sufficiently long in the SRC range for dispersoid formation, these dispersoids can act as potent grain refiners and possibly enhance elevated temperature properties. A combination of both processes by using SRC alloys in the NRC equipment may lead to pressure tight castings with low porosity and finer grain structure than can be achieved with NRC on its own, and consequently, better mechanical properties.