Cooling slope casting to obtain thixotropic feedstock

Thixoforming, and related semi-solid processing routes for metallic alloys, require feedstock with a non-dendritic microstructure in the semi-solid state. The material then behaves in a thixotropic way in that, when it is sheared it flows and can be forced to fill a die and, when it is allowed to stand it thickens again. The New Rheocasting (the NRC process) is a recently developed semi-solid processing route. There are two versions of this route. In one, molten alloy is poured directly into a tilted mould and, through careful temperature control during cooling, a spheroidal semi-solid microstructure is achieved. The material in the mould is then upended into a shot sleeve and hence forced into a die. Alternatively, the molten alloy is poured onto a cooling slope and thence into a mould before processing. The aim of the work described in this paper was to develop understanding of the microstructural development during the initial stages of this process. The results for pouring A356 aluminium alloy via a cooling slope into a mould are presented.