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Aluminium alloys, including both foundry and wrought alloys, have been extensively used for light-weight structural and functional applications. A grain refined as-cast microstructure is generally highly desirable for either subsequent processing ability or mechanical properties of the finished components. In this thesis, the grain refined microstructures in Al alloys have been achieved by intensive melt shearing using the melt conditioning by advanced shearing technology (MCAST) without deliberate grain refiner additions. Such grain refinement has been attributed to the enhanced heterogeneous nucleation on the dispersed oxide particles. It has been established that the naturally occurring oxides in molten Al alloys normally have a good crystallographic match with the a-Al phase, indicating the high potency of oxide particles as the nucleation sites of the a-Al phase. The governing factors for these oxide particles to be effective grain refiners in Al alloys have been proposed, including the achievement of good wetting between oxide particles and liquid aluminium, a sufficient number density and uniform spatial distribution of the dispersed oxide particles, and near equilibrium kinetic conditions in liquid alloys. In the present study, near equilibrium kinetic conditions can be achieved by intensive melt shearing using a twin screw mechanism, which has been confirmed by the observed equilibrium a-AlFeSi phase in a cast Al alloy and the transformation from g- to a-Al2O3 at 740±20oC under intensive shearing. For different alloy systems, depending on the alloy system, and melting conditions, due to the particular types of oxide formed and its crystallographic and chemical characteristics, the nucleation site of the nucleated phase is different. Specifically, MgAl2O4 relative to MgO, and a-Al2O3 relative to g-Al2O3, have higher potency as heterogeneous nucleation sites of a-Al phase in Al alloys. In future, the modification of the crystallographic match, and of the other surface characteristics related to the interfacial energy between the specific oxides and nucleated phase by trace alloying addition through segregation to the interface between oxides and nucleated phases combined with physical melt processing (such as intensive shearing in the present study) should be investigated in more detail.
The industrial practice of grain refinement of aluminium alloys involves the addition of inoculant particles to initiate alpha-aluminium grains at small undercoolings. This results in a uniformly fine, equiaxed as-cast microstructure and is commonly achieved using Al-Ti-B additions. The phase responsible for initiation of grains in aluminium melts inoculated with Al-Ti-B was determined during the 1990s; since that time, scientific understanding of grain refinement has advanced rapidly. However, one of the main problems of addition inoculants is impurities which is added to the melt and may affect the desired characteristics of the product. With regards to this problem other methods of refinement and the mechanisms of refining have not been fully understood and prediction of as-cast Microstructures in aluminium alloys has much scope for improvement. In this thesis: 1-Factors in establishing equiaxed microstructure were analysed and the origin of equiaxed grains were explored. Then the nucleation process and the involved mechanisms were investigated in depth and control of nucleation process to achieve a fine and uniform structure was set as target. 2-Refinement of microstructure with introduction of shearing was evaluated and the process of refinement in the mushy zone (semisolid state) as a base line was established. Then introduction of shearing above liquidus as a development was analysed and outstanding refinement was seen with shearing above liquidus which have not been investigated properly elsewhere. 3- The mechanisms of refinement by introducing shearing were investigated and the refining mechanisms below and specifically above liquidus were investigated systematically. As results an appropriate understanding about the mechanisms of nucleation and refinement above liquidus was established. 4- Finally, with simulation the most dominant factor in approaching fine grain size by applying shear was identified and the results of experimental examination was verified by simulation.