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Mechanisms of gas and shrinkage porosity formation in solidifying shear bands

Bhagavath, S; Gong, Z; Wigger, T; Shah, S; Ghaffari, B; Li, M; Marathe, S; ... Lee, PD; + view all (2022) Mechanisms of gas and shrinkage porosity formation in solidifying shear bands. Journal of Materials Processing Technology , 299 , Article 117338. 10.1016/j.jmatprotec.2021.117338.

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Abstract

In specialised solidification processing techniques such as High Pressure Die Casting, Twin-Roll Casting and others, an additional external deformation load is applied to achieve the required shape, leading to the formation of microstructural features such as shear bands. The mechanism for forming these features is believed to be dependent on dynamically evolving strain fields, which are dependent on the local solid fraction, applied strain rates and casting geometry. To investigate this, a semisolid (∼ 50 % solid fraction) Al-10 wt.% Cu alloy is isothermally injected into a bespoke die using a custom-designed thermo-mechanical rig. The semisolid deformation, formation of Cu-rich dilatant bands and subsequent pore nucleation and growth are captured using fast synchrotron X-ray radiography. The local normal and shear strains acting on the mush are quantified using digital image correlation to identify the dilatant shear bands and the dominant local strain component. Correlating the radiographs with strain maps reveals that gas pores within the dilated interstices grow, while those in compressed regions are squeezed out. A linear correlation between accumulated volumetric strain and porosity volume fraction demonstrates that higher dilations give rise to a local increase in both gas and shrinkage porosity.

Type: Article
Title: Mechanisms of gas and shrinkage porosity formation in solidifying shear bands
DOI: 10.1016/j.jmatprotec.2021.117338
Publisher version: https://doi.org/10.1016/j.jmatprotec.2021.117338
Language: English
Additional information: This version is the author accepted manuscript. For information on re-use, please refer to the publisher’s terms and conditions.
Keywords: Semisolid; Dilatancy; X-ray radiography; Digital image correlation; Gas porosity
UCL classification: UCL
UCL > Provost and Vice Provost Offices > UCL BEAMS
UCL > Provost and Vice Provost Offices > UCL BEAMS > Faculty of Engineering Science
UCL > Provost and Vice Provost Offices > UCL BEAMS > Faculty of Engineering Science > Dept of Mechanical Engineering
URI: https://discovery.ucl.ac.uk/id/eprint/10134572
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