Abstract:
A semi-solid processing technique combining a cooling plate and various mold materials is developed to produce high quality gray cast iron components. Flow behavior of semi-solid slurry along an inclined cooling plate is studied to establish the effect of plate orientation on the integrity of cast products. The concept of multiple-stage cooling is discussed by considering cooling rates at different stages of processing along the cooling plate and in sand, graphite and metallic molds to show the significance of cooling rate in determining component microstructure. The morphology of microstructure in cast components is discussed and image analysis results presented. A refined microstructure of primary austenite and graphite, and their characteristics associated with the use of different mold materials are reported. Angle of inclination of plate is shown to influence the morphology and quantity of precipitated phases. Finally, the effects of cooling plate and mold material on Vickers hardness and mechanical strength of cast components are discussed.