Grain refinement of ASTM A356 aluminum alloy using sloping plate process through gravity die casting

Sloping plate flow is used for enhancement of material properties through grain refinement in gravity die casting of Aluminum alloy ASTM A356. The castings are prepared with different slope angles of an 800 mm long, naturally cooled stainless steel plate. The specimens obtained are then tested for tensile strength and elongation. Microstructure of the cast specimens is observed and conclusions drawn on the grain size and precipitate morphology as a function of angle of sloping plate. Analysis is presented for the boundary layer created while the material flows over the plate. An indication of the boundary layer thickness is determined by measuring the thickness of the residual metal layer on the plate after casting. An analytical solution of the boundary layer thickness is also presented. It is shown that the calculated boundary layer thickness and the thickness of the layer of material left in the channel after casting are in good agreement. Moreover, microstructure examination and tensile tests show that best properties are achieved with a 60° sloping plate.