Studies on addition of inclusions to molten aluminum using a novel technique

Abstract

Considerable initiatives have often been taken to introduce specific solid particles directly into molten metals in a desirable quantity, but little success has been achieved, particularly in the case of reactive particles. Therefore, alternative routes such as production of solid particles through chemical reactions within the melt are often used. While these methods are capable of producing solid particles within the melt, the chemistry of the melt changes and control of particle size and chemistry is difficult. In the present study, a direct addition technique has been used to introduce many types of inclusions into liquid aluminum and Al-Si alloys, irrespective of their wettability and chemical reactivity, while preserving the surface characteristics and melt chemistry. A uniform particle distribution can be obtained even at low volume fraction of addition and with particle sizes of the order of 2 to 5 µm. This technique allows valuable information regarding the behavior of many inclusions, such as TiB₂, TiC, SrO, and Sr(OH)₂, in liquid aluminum to be studied. Several such examples are presented.