ZELNÍČKOVÁ Marta: Optimizing of heat treatment of casting produced by SEED method. This work deals with designing optimum heat treatment method for casting alloy AlSi7Mg0,3, cast by SEED. Different temperature and times are tested in regimes of heat treatment, mechanical properties are determined with dependence of on the heat treatment method and optimal temperature regime is determined from the detected values.

In several applications of casting, dendritic microstructure is not desirable as it results in poor mechanical properties. Enhancing fluid flow in the mushy zone by stirring is one of the means to suppress this dendritic growth. Strong fluid flow detaches the dendrites formed at the solid-liquid interface and carries them into the mould to form slurry. When this slurry solidifies, the microstructure is characterized by globular, non-dendritic primary phase particles, separated and enclosed by a near-eutectic lower-melting secondary phase. This property represents a great potential for further processing in semisolid forming (SSF) by various techniques such as pressure die casting and forging. Among all currently available methods, linear electromagnetic (EM) stirring is considered as one of the most suitable routes for large scale production of semisolid feed stock. One of the biggest advantages of EM stirring is that the stirring intensity and direction can be modulated externally and in a non-intrusive manner. With this viewpoint, the primary objective of the present research is to investigate rheocasting using linear electromagnetic stirring. A systematic development of a linear electromagnetic stirrer (LEMS) is the subject of the first part of the thesis. The LEMS consists of a set of six primary coils displaced in space. These coils are excited by a three-phase power supply to produce an axially travelling magnetic field. The metal to be stirred is placed in the annular space of the stirrer. The travelling field induces secondary current in the molten metal. The current and magnetic fields interact to generate a net mechanical force in the metal, commonly termed as the Lorentz force. The molten metal is stirred under the influence of this force. Two prototype stirrers, one for low melting alloys and the other for aluminium alloys are developed. The stirrers are characterized by measuring forces on low melting point alloy and on solid aluminum cylinders placed inside the annular space of the stirrer. As an outcome of these tests, a non-intrusive method of detecting stirring of liquid metal is developed. The development of a rheocasting mould for the LEMS forms the second part of the work presented in the thesis. The mould design and cooling arrangement are such that solidification in the mould is primarily unidirectional. Heat from the solidifying metal is extracted at the bottom of the mould, so that the axisymmetric EM stirring effectively shears the dendrites formed at the solid-liquid interface. The outer surface of the mould is cooled with water or air exiting from 64 jets, each of 4 mm diameter. Such an arrangement provides a high heat transfer coefficient and a wide range of cooling rate in the metal ranging from 0.01 to 10 K/s. Temperature is measured at various depths in the solidifying melt and at other key locations in the mould to assess the various heat transfer mechanisms. The results from the rheocasting experiments using the above mould and LEMS are presented in the third and final part of the thesis. Such studies are required for understanding the solidification process in presence of electromagnetic stirring and for highlighting the important issues connecting solidification, fluid flow, dendrite fragmentation and the resulting microstructure. A series of experiments are performed with A356 (Al-7Si-0.3Mg) alloy. Experiments are conducted with various combinations of operating parameters, and the resulting microstructures and cooling curves at various locations are examined. The key process parameters are stirring current, cooling rate, pouring temperature, and stirring current frequency. The parametric studies also include the case without EM stirring in which liquid aluminium is poured into the rheocast mould without powering the LEMS. It is found that stirring at high currents produces non-dendritic microstructures at all locations of the billet. For lower currents, however, dendritic microstructures are observed in regions outside the zone of active stirring. Stirring also enhances heat loss from the exposed top surface, leading to solid front advancement from the top as well. Without EM stirring, microstructures are found to be dendritic everywhere. The percentage of primary α-Al phase and its number density are found to increase with stirring intensity. With a decrease in cooling rate with air as the coolant, the average grain size of primary α-Al phase increases. Excitation frequency is found to be an important parameter, with lower frequencies generating a more uniform force field distribution, and higher frequencies enhancing induction heating. At higher frequencies, the effect of higher induction heating results in the formation of larger and coarser primary phase grains. This phenomenon has led to the development of a one-step process for rheocasting and heat treatment of billets.

Submitted by Johnny Rodrigues (johnnyrodrigues@ufcg.edu.br) on 2018-04-23T15:36:04Z No. of bitstreams: 1 MARIA VITÓRIA DIAS CARNEIRO - TESE PPGEP 2013..pdf: 1590820 bytes, checksum: 3850fa3d6d23bb523a2b7b2723d20527 (MD5) / Made available in DSpace on 2018-04-23T15:36:04Z (GMT). No. of bitstreams: 1 MARIA VITÓRIA DIAS CARNEIRO - TESE PPGEP 2013..pdf: 1590820 bytes, checksum: 3850fa3d6d23bb523a2b7b2723d20527 (MD5) Previous issue date: 2013-08-30 / Este trabalho teve como objetivo enriquecer nutricionalmente o bagaço do pedúnculo de caju utilizando-se a levedura Saccharomyces cerevisiae, através da fermentação semissólida, visando à produção de um suplemento nutricional enriquecido para ser incluído nas rações de codornas. Os resultados sugeriram que o tempo de 12 horas apresentou maior teor de proteína 15,21%, com aumento percentual proteico de 83,80%. Posteriormente foram realizados dois experimentos. Objetivou-se, no primeiro no experimento, determinar os valores da energia metabolizável do bagaço do caju enriquecido incluindo nas dietas com codornas japonesas em postura. Para determinar os valores da energia metabolizável aparente (EMA) energia metabolizável aparente corrigida pelo balanço de nitrogênio (EMAn) e coeficiente de metabolização da energia bruta (CMEB) foi utilizado o método tradicional de coleta total das excretas com codornas japonesas em postura com 60 dias de idade, em um delineamento experimental inteiramente ao acaso, com três tratamentos e cinco repetições e oito aves por unidade experimental. Obteve-se 2.539,62 kcal/kg e 2.421,81 kcal/kg, a 30% de substituição, respectivamente. Os coeficientes de metabolização da energia bruta foram 68% para 15% de substituição e 67% para 30% de substituição da dieta-referência. Esses valores evidenciam a influência do nível de inclusão do alimento alternativo sobre os valores de EMA e EMAn na dieta. No segundo experimento utilizaram-se 160 codornas japonesas com 86 dias de idade, produção média de 92% e peso inicial de 170 gramas, distribuídas em um delineamento experimental inteiramente ao acaso, com quatro tratamentos (0; 10; 20 e 30%) e cinco repetições e oito aves por unidade experimental com inclusão do bagaço enriquecido. O aumento da inclusão do bagaço do pedúnculo do caju enriquecido com a levedura Saccharomyces cerevisiae é diretamente proporcional a maior concentração de 10,65% para peso do ovo das codornas japonesas. Sempre que o bagaço do pedúnculo do caju enriquecido era incluído nas rações aumenta, proporciona maior concentração na pigmentação da gema dos ovos das codornas japonesas; sua inclusão nas dietas das codornas japonesas é economicamente viável e não compromete os índices zootécnicos; no entanto, o aumento dos níveis do bagaço do pedúnculo do caju deverá ser avaliado de acordo com o aspecto econômico e mercadológico. / This work was carried out with the aim of studying the enlargement of experimental scale process of nutritional enrichment of bagasse of stalk of cashew apple using the yeast Saccharomyces cerevisae, through the semisolid fermentation aiming at the production of a nutritional supplement enriched to replace, partly, commercial supplements in feed of quail. It was also studied the proteic increase using rotary drum bioreactor and the results suggested that the time at 12 hours had a higher protein content of 15,21%, with a percentage increase of 83,80% of protein. Later this material already enriched was formulated as feed to Japanese quail (Coturnix coturnix japonica) in order to determine the metabolized energy of the bagasse of stalk of cashew apple enriched. It were used 120 quails with 60 days of age, distributed in a completely randomized design with three treatments ( one reference diet and two replacement levels) with five replicates of eight quails per experimental unit. The levels of apparent metabolized energy (AME) and apparent metabolized energy corrected (AMEn), in Kcal/kg of natural matter from bagasse of stalk of cashew apple enriched with yeast, were 2.522,20 and 2465,93, in the level of 15% replacement and 2539,62 and 2421,81, with replacement of 30% of the diet reference, respectively. The values of dry matter, crude protein, crude fiber, calcium and phosphorus were 83,80%, 15,20%, 149,90g, 110g and 200g, respectively. From these results were verified the effects of bagasse of stalk of cashew apple in the diet of Japanese quails on performance, economic analysis and quality of eggs. It were used 160 quails from the species Coturnix coturnix japonica with 86 days of age, with an average production of 92%, then it was conducted an experiment in a completely randomized design, with four treatments (reference feed + 10, 20 and 30% of replacement) five replicates and eight quails per experiment unit, with four periods of 21 days. The bagasse of stalk of cashew apple enriched with 10,65% reached the highest egg weight, its replacement is economically feasible and does not compromise the zootecnic indexes, however, increased levels of bagasse of stalk of cashew apple should be evaluated according to the aspects of economics and market. For that the percentage of protein of bagasse of stalk of cashew apple remains unchanged, storage should be in a freezer after dry.

Neste trabalho foi avaliada a permeação/penetração cutânea in vitro (pele suína) de propionato de clobetasol nanoencapsulado incorporado em um semissólido, empregando células de difusão de Franz. A nanoencapsulação foi capaz de reduzir a quantidade de fármaco que penetra nas camadas da pele (estrato córneo, epiderme e derme) sem alterar a forma (distribuição percentual) como o propionato de clobetasol se distribui. A adequabilidade de diferentes membranas sintéticas (acetato de celulose, policarbonato e membrana de diálise) para a avaliação da liberação in vitro, empregando células de difusão de Franz, a partir desta formulação foi também estudada. A partir da combinação de diferentes técnicas analíticas (espalhamento de luz dinâmica, microscopias eletrônicas de transmissão e varredura) foi observado que a membrana de menor tamanho de poro (membrana de diálise, 12 kDa de cut off) é a mais adequada para a condução deste tipo de avaliação, pois é a única capaz de evitar a passagem de nanocápsulas íntegras da formulação para o meio receptor das células de difusão, em detrimento das membranas de policarbonato e acetato de celulose (0,05 μm e 0,45 μm de tamanho de poro, respectivamente). Além disso, uma nova estratégia para a avaliação da liberação in vitro de fármacos associados a nanocápsulas de núcleo lipídico, combinando fluxo contínuo de meio de liberação e sacos de diálise foi proposta neste trabalho. A técnica mostrou-se adequada para a obtenção do perfil de liberação in vitro a partir de suspensões de nanocápsulas contendo diferentes fármacos modelo (prednisolona e propionato de clobetasol), possibilitando a diferenciação destes sistemas de soluções contendo os fármacos livres, graficamente e pelos valores de fluxo calculados. Adicionalmente, esta estratégia mostrou-se apropriada para a manutenção da concentração de fármaco no meio de liberação afastada da saturação, contribuindo para o atendimento da condição sink. Ainda, classificamos o sistema como um protótipo semi-automatizado para a avaliação da liberação in vitro de fármacos, capaz de gerar resultados com maior precisão em relação à diálise convencional. / The in vitro cutaneous permeation/penetration (porcine skin) of clobetasol propionate-loaded lipid-core nanocapsules incorporated into a semisolid dosage form was evaluated, using the Franz diffusion cells technique. It was shown that the nanoencapsulation was able to reduce the drug amount penetration into skin layers (stratum corneum, epidermis and dermis) without changing the way (percentual distribution) that it was distributed. The suitability of different synthetic membranes (cellulose acetate, polycarbonate, and dialysis membrane) to assess the in vitro drug release using Franz diffusion cells from this formulation was also studied. It was ascertained by combining different analytical techniques (dynamic light scattering, scanning and transmition electron microscopy) that the membrane with smaller pore size (dialysis membrane, 12 kDa cut off) is the most appropriate for conducting this kind of study, because it is the only one able of preventing the passage of intact nanocapsules from formulation to Franz diffusion cells receptor media, instead of polycarbonate and cellulose acetate membranes (0.05 and 0.45 pore size, respectively). In addition, a new strategy to assess in vitro drug release drug-loaded lipid-core nanocapsules was proposed, associating continuous flow of release media and dialysis sac. The proposed system was adequate to assess the in vitro drug release profiles from nanocapsule suspensions containing different model drugs (prednisolone and clobetasol propionate), enabling the differentiation of these systems from drug solutions, graphically and by the calculated flux values. Furthermore, this strategy was suitable to maintain the drug concentration into release media far away from saturation, contributing to the sink condition. Also, the proposed system was described as a semi-automated prototype for in vitro drug release evaluation, able to produce results with greater accuracy than conventional dialysis technique.

Neste trabalho foi avaliada a permeação/penetração cutânea in vitro (pele suína) de propionato de clobetasol nanoencapsulado incorporado em um semissólido, empregando células de difusão de Franz. A nanoencapsulação foi capaz de reduzir a quantidade de fármaco que penetra nas camadas da pele (estrato córneo, epiderme e derme) sem alterar a forma (distribuição percentual) como o propionato de clobetasol se distribui. A adequabilidade de diferentes membranas sintéticas (acetato de celulose, policarbonato e membrana de diálise) para a avaliação da liberação in vitro, empregando células de difusão de Franz, a partir desta formulação foi também estudada. A partir da combinação de diferentes técnicas analíticas (espalhamento de luz dinâmica, microscopias eletrônicas de transmissão e varredura) foi observado que a membrana de menor tamanho de poro (membrana de diálise, 12 kDa de cut off) é a mais adequada para a condução deste tipo de avaliação, pois é a única capaz de evitar a passagem de nanocápsulas íntegras da formulação para o meio receptor das células de difusão, em detrimento das membranas de policarbonato e acetato de celulose (0,05 μm e 0,45 μm de tamanho de poro, respectivamente). Além disso, uma nova estratégia para a avaliação da liberação in vitro de fármacos associados a nanocápsulas de núcleo lipídico, combinando fluxo contínuo de meio de liberação e sacos de diálise foi proposta neste trabalho. A técnica mostrou-se adequada para a obtenção do perfil de liberação in vitro a partir de suspensões de nanocápsulas contendo diferentes fármacos modelo (prednisolona e propionato de clobetasol), possibilitando a diferenciação destes sistemas de soluções contendo os fármacos livres, graficamente e pelos valores de fluxo calculados. Adicionalmente, esta estratégia mostrou-se apropriada para a manutenção da concentração de fármaco no meio de liberação afastada da saturação, contribuindo para o atendimento da condição sink. Ainda, classificamos o sistema como um protótipo semi-automatizado para a avaliação da liberação in vitro de fármacos, capaz de gerar resultados com maior precisão em relação à diálise convencional. / The in vitro cutaneous permeation/penetration (porcine skin) of clobetasol propionate-loaded lipid-core nanocapsules incorporated into a semisolid dosage form was evaluated, using the Franz diffusion cells technique. It was shown that the nanoencapsulation was able to reduce the drug amount penetration into skin layers (stratum corneum, epidermis and dermis) without changing the way (percentual distribution) that it was distributed. The suitability of different synthetic membranes (cellulose acetate, polycarbonate, and dialysis membrane) to assess the in vitro drug release using Franz diffusion cells from this formulation was also studied. It was ascertained by combining different analytical techniques (dynamic light scattering, scanning and transmition electron microscopy) that the membrane with smaller pore size (dialysis membrane, 12 kDa cut off) is the most appropriate for conducting this kind of study, because it is the only one able of preventing the passage of intact nanocapsules from formulation to Franz diffusion cells receptor media, instead of polycarbonate and cellulose acetate membranes (0.05 and 0.45 pore size, respectively). In addition, a new strategy to assess in vitro drug release drug-loaded lipid-core nanocapsules was proposed, associating continuous flow of release media and dialysis sac. The proposed system was adequate to assess the in vitro drug release profiles from nanocapsule suspensions containing different model drugs (prednisolone and clobetasol propionate), enabling the differentiation of these systems from drug solutions, graphically and by the calculated flux values. Furthermore, this strategy was suitable to maintain the drug concentration into release media far away from saturation, contributing to the sink condition. Also, the proposed system was described as a semi-automated prototype for in vitro drug release evaluation, able to produce results with greater accuracy than conventional dialysis technique.

Neste trabalho foi avaliada a permeação/penetração cutânea in vitro (pele suína) de propionato de clobetasol nanoencapsulado incorporado em um semissólido, empregando células de difusão de Franz. A nanoencapsulação foi capaz de reduzir a quantidade de fármaco que penetra nas camadas da pele (estrato córneo, epiderme e derme) sem alterar a forma (distribuição percentual) como o propionato de clobetasol se distribui. A adequabilidade de diferentes membranas sintéticas (acetato de celulose, policarbonato e membrana de diálise) para a avaliação da liberação in vitro, empregando células de difusão de Franz, a partir desta formulação foi também estudada. A partir da combinação de diferentes técnicas analíticas (espalhamento de luz dinâmica, microscopias eletrônicas de transmissão e varredura) foi observado que a membrana de menor tamanho de poro (membrana de diálise, 12 kDa de cut off) é a mais adequada para a condução deste tipo de avaliação, pois é a única capaz de evitar a passagem de nanocápsulas íntegras da formulação para o meio receptor das células de difusão, em detrimento das membranas de policarbonato e acetato de celulose (0,05 μm e 0,45 μm de tamanho de poro, respectivamente). Além disso, uma nova estratégia para a avaliação da liberação in vitro de fármacos associados a nanocápsulas de núcleo lipídico, combinando fluxo contínuo de meio de liberação e sacos de diálise foi proposta neste trabalho. A técnica mostrou-se adequada para a obtenção do perfil de liberação in vitro a partir de suspensões de nanocápsulas contendo diferentes fármacos modelo (prednisolona e propionato de clobetasol), possibilitando a diferenciação destes sistemas de soluções contendo os fármacos livres, graficamente e pelos valores de fluxo calculados. Adicionalmente, esta estratégia mostrou-se apropriada para a manutenção da concentração de fármaco no meio de liberação afastada da saturação, contribuindo para o atendimento da condição sink. Ainda, classificamos o sistema como um protótipo semi-automatizado para a avaliação da liberação in vitro de fármacos, capaz de gerar resultados com maior precisão em relação à diálise convencional. / The in vitro cutaneous permeation/penetration (porcine skin) of clobetasol propionate-loaded lipid-core nanocapsules incorporated into a semisolid dosage form was evaluated, using the Franz diffusion cells technique. It was shown that the nanoencapsulation was able to reduce the drug amount penetration into skin layers (stratum corneum, epidermis and dermis) without changing the way (percentual distribution) that it was distributed. The suitability of different synthetic membranes (cellulose acetate, polycarbonate, and dialysis membrane) to assess the in vitro drug release using Franz diffusion cells from this formulation was also studied. It was ascertained by combining different analytical techniques (dynamic light scattering, scanning and transmition electron microscopy) that the membrane with smaller pore size (dialysis membrane, 12 kDa cut off) is the most appropriate for conducting this kind of study, because it is the only one able of preventing the passage of intact nanocapsules from formulation to Franz diffusion cells receptor media, instead of polycarbonate and cellulose acetate membranes (0.05 and 0.45 pore size, respectively). In addition, a new strategy to assess in vitro drug release drug-loaded lipid-core nanocapsules was proposed, associating continuous flow of release media and dialysis sac. The proposed system was adequate to assess the in vitro drug release profiles from nanocapsule suspensions containing different model drugs (prednisolone and clobetasol propionate), enabling the differentiation of these systems from drug solutions, graphically and by the calculated flux values. Furthermore, this strategy was suitable to maintain the drug concentration into release media far away from saturation, contributing to the sink condition. Also, the proposed system was described as a semi-automated prototype for in vitro drug release evaluation, able to produce results with greater accuracy than conventional dialysis technique.

In this thesis, we present an experimental and numerical study of globularization during reheating of thixocast billet having non-dendritic microstructure. The process of reheating is an important step in the semisolid processing and is essential to control its microstructure and hence its mechanical properties. Material chosen for this study is Aluminum alloy, A356. The primary focus of this study is the heat treatment below eutectic temperature i.e. transformation in solid phase. It is found that during short duration heat treatment, globularization of primary α grains and spheroidization of eutectic Si flakes take place which improves the mechanical properties of semisolid cast products significantly. A prolonged heat treatment is found to degrade the properties of castings since it enhances the porosity and coarsening of Si. The study suggests that a precise heat treatment practice can be designed to improve the semisolid microstructure. A computational model based on Phase field approach has been proposed to study this phenomena. Predictions based on this model are qualitatively compared with corresponding experimental observations. Since eutectics form an important step in multiphase solidification, an attempt has been made to develop an enthalpy based explicit micro-scale model for eutectic solidification. In this preliminary study, growth of adjacent α and β phases in a two dimensional Eulerian framework has been simulated. The model is qualitatively validated with Jackson Hunt theory. Results show expected eutectic growth. This methodology promises significant saving in computational time compared to existing numerical models.

The challenges of weight reduction and good strength in automotive industry have drawn considerable interest in thixocasting technologies. Joining of such components with conventional fusion welding creates voids, hot cracking, distortion in shape, and more importantly evolution of dendritic microstructure that ultimately would lead to inferior mechanical properties of the weld region. Thus, the purpose of making thixocast component is lost. The friction welding which is a solid state joining process can avoid defects associated with melting and solidification in a typical fusion weld and can be a promising alternative. This process produces a weld under compressive force at the contact of workpieces rotating or moving relative to one another to produce heat and plastically displacing material from the faying surfaces. Research on semisolid processing has its origin in the early 1970s. However, from the literature survey on semisolid processing it is clear that, till date, not much work has been done in field of joining of semisolid processed components. In the area of solid state welding, in particular, it is not at all explored. In view of this, the present work is focused on exploration of joining of Thixocast A356 Aluminium alloy component by friction welding and comparison of its performance with friction weld of conventionally cast sample of the same alloy. The study is carried out experimentally as well as numerically. Moreover, the material behaviour of thixocast component at elevated temperature in solid state is also described with the help of processing maps and constitutive modelling. The hot workability of thixocast and conventionally cast A356 alloy is evaluated with the help of processing maps developed on the basis of the dynamic materials model approach using the flow stress data obtained from the isothermal compression test in wide range of temperature (300-500℃) and strain rates (0.001s-1-10s-1). The domains of the processing map are interpreted in terms of the associated microstructural mechanism. On comparing the flow stress at elevated temperature of thixocast and conventionally cast A356 alloy samples, it is observed that the flow stress of the latter showed higher value at different strain level, temperature and strain rates. This indicates that the flow property of the thixocast alloy sample is better than that of the conventionally cast one (i.e. response to plastic flow is better for the former); while at room temperature thixocast sample has higher strength. Moreover to investigate the general nature of the influence of strain, strain rate and temperature on the compressive deformation characteristics of thixocast A356 and conventionally cast A356 aluminium alloy, a comprehensive model describing the relationship of the flow stress, strain rate and temperature of the alloys at elevated temperatures is proposed by hyperbolic-sine Arrhenius-type equation and Johnson-Cook model. The validity of descriptive results based on the proposed constitutive equation is also investigated and a comparison between two constitutive models is also made. In order to numerically model the friction welding process of a thixocast A356 aluminium alloy and conventionally cast alloy of same material using a finite element method (FEM), temperature dependent physical properties, mechanical properties as well as viscoplastic constitutive equations were used in the model. A two- dimensional axisymmetric finite element model has been developed. The modelling is based on a coupled thermomechanical approach. First, a nonlinear, transient two-dimensional heat transfer model is developed to determine the temperature fields. Later, the temperature fields are used as input for a nonlinear, two-dimensional structural model in order to predict the distortions and von Mises stress. The finite element models are parametrically built using APDL (ANSYS Parametric Design Language) provided by ANSYS. The validation of the model is carried out by comparing with the experiment. Once validated, the thermomechanical model was used to perform parametric studies in order to investigate effects of various process parameters on temperature and stress distribution in the workpieces. This helps in deciding the range of parameters for friction welding experiments in order to get good weld. Both thixocast and conventionally cast samples exhibited similar temperature distribution during the friction welding process, because of identical thermophysical properties. The magnitude of von Mises stress distribution during friction welding of thixocast A356 sample is found to be lower than that of the conventionally cast sample. It is because of their different constitutive behaviour at elevated temperature. Moreover, the developed FEM model can be successfully used to predict the residual stress at various locations for different set of parameters and geometry for friction welding of thixocast and conventionally cast A356 alloy. This helps in reducing time consuming and expensive experiments on residual stress measurement. The chosen experiments based on Taguchi L27 orthogonal array were conducted on the friction welding machine which works on the principles of continuous drive-mechanism. The experimental specimens were machined from thixocast A356 aluminium alloy connecting rods as well as conventionally cast A356 aluminium alloy ingot in the form of cylindrical bars of dimensions 85mm length and 20mm diameter. The parameters used for welding were friction pressure, rpm, forge pressure, burn-off, and upset pressure. The effects of welding parameters on performance characteristics (i.e. tensile strength and weld efficiency) were evaluated. Taguchi method was applied to investigate the influence of each parameter on strength of joints and evaluate the combination of parameters that leads to the highest weld strength. Accordingly optimum process parameters was identified which helps in achieving the tensile strength of more than parent material. The optimized process parameters for friction welding of thixocast A356 aluminium alloy are rpm = 500, friction pressure = 60, upset time = 5, upset pressure = 100 and burn off = 5. The empirical relationships were also developed to predict the tensile strength. The developed relationship can be effectively used to predict the tensile strength of welded joint with a correlation coefficient of 0.86, which indicates the strong positive relationship between predicted and experimental data. Friction welding of thixocast A356 aluminium alloy helps to achieve very fine eutectic silicon particles of the order of 0.4 at the interface due to severe plastic deformation taking place during welding. Obtaining such fine eutectic silicon particles is difficult to be achieved within few seconds of processing by any other method. The hardness variation of friction welded thixocast alloy shows higher value as compared to that of a conventionally cast sample in the heat affected zone, which indicates better weld strength of the former. This was also confirmed by the tensile strength studied and fatigue test. This indicates that weldability of cast alloys will get improved if the microstructure is modified to globular type.

In view of the significant advantages offered by semi-solid processing, such as reduction in number of intermediate processing steps and energy input, and the potential for improving component complexity, it is of paramount interest to develop indigenous technology for semi-solid forming of steels, especially nuclear grade steels. For adopting semisolid processing as an alternative method of manufacturing of steels, it is essential to study the amenability of the steel for the process, understand the fundamental mechanisms of micro structural evolution and evaluate the mechanical properties of the steel after processing. To achieve this goal, the present work attempts to appraise the amenability of a low-carbon variant of 18%Cr-8%Ni austenitic stainless steel (304L SS) for semi-solid processing. Among the many requirements of the feedstock in semi-solid processing, a key feature that makes it amenable for semi-solid processing is the unique microstructure containing solid spheroids in a liquid matrix, thereby enabling thixo-tropic behaviour in the alloy. To understand the micro structural evolution in the steel, during major steps of semi-solid processing (partial melting, soaking and solidification), several experiments are carried out by varying the key parameters such as temperature, soaking time and cooling rate. Experimental results are analyzed in details to specify the effects of these parameters on the microstructure of semi-solid processed steel. The analysis indicates different phase transformation sequences during solidification of the steel from its semi-solid state. On the basis of experimental results, mechanism for micro structural evolution during partial melting and subsequent solidification of 304L SS is proposed. The effect of soaking time on the size and shape of the solid globules is analyzed using the theory of anisotropic Ostwald ripening. The semi-solid processing parameters, such as soaking time and temperature, are found to have significant influence on the globule distribution, globule shape, ferrite distribution and dislocation density, which in turn govern the tensile behaviour and mechanical properties of the steel after processing. Semi-solid processed 304L SS exhibits lower yield strength, ultimate tensile strength and higher strain hardening in temperature range 303–873K compared to as-received (rolled and subsequently annealed) 304L SS. However, semi-solid processed steel shows higher uniform elongation and fracture strain compared to the as-received steel. A pronounced effect of semi-solid processing is also found on the high temperature plasticity and dynamic recrystallization pattern. This work demonstrates the amenability of 300 series austenitic stainless steels for semi-solid processing. The investigation provides the significant insight into the mechanism of micro structural evolution in austenitic stainless steels during semi-solid processing and the important information on the mechanical properties and plastic flow behavior of the semi-solid processed steel. The results give crucial inputs for the optimization of processing parameters for obtaining the desired property in the product, and also for deciding the potential industrial application of the process.

In most casting applications, dendritic microstructure morphology is not desired because it leads to poor mechanical properties. Forced convection causing sufficient shearing in the mushy zone of the partially solidified melt is one of the means to suppress this dendritic growth. The dendrites formed at the solid-liquid interface are detached and carried away due to strong fluid flow to form slurry. This slurry, consisting of rosette or globular particles, provides less resistance to flow even at a high solid fraction and can easily fill the die-cavity. The stated principle is the basis of a new manufacturing technology called “semi-solid forming” (SSF), in which metal alloys are cast in the semi-solid state. This technique has numerous advantages over other existing commercial casting processes, such as reduction of macrosegregation, reduction of porosity and low forming efforts. Among all currently available methods available for large scale production of semisolid slurry, the cooling slope is considered to be a simple but effective method because of its simple design and easy control of process parameters, low equipment and running costs, high production efficiency and reduced inhomogeneity. With this perspective, the primary objective of the present research is to investigate, both experimentally and numerically, convective heat transfer and solidification on a cooling slope, in addition to the study of final microstructure of the cast billets. Some key process parameters are identified, namely pouring temperature, slope angle, slope length, and slope cooling rate. A systematic scaling analysis is performed in order to understand the relative importance of the parameters in influencing the final properties of the slurry and microstructure after solidification. A major part of the present work deals with the development of an experimental set up with careful consideration of the range of process parameters involved by treating the cooling slope as a heat exchanger. Subsequently, a comprehensive numerical model is developed to predict the flow, heat transfer, species concentration solid fraction distribution of aluminum alloy melt while flowing down the cooling slope. The model uses a variable viscosity relation for slurry. The metal-air interface at the top during the melt flow is tracked using a volume of fluid (VOF) method. Solidification is modeled using an enthalpy based approach and a volume averaged technique. The mushy region is modeled as a multi-layered porous medium consisting of fixed columnar dendrites and mobile equiaxed or fragmented grains. In addition, the solidification model also incorporates a fragmentation criterion and solid phase movement. The effects of key process parameters on flow behavior involving velocity distribution, temperature distribution, solid fractions at the slope exit, and macrosegregation, are studied numerically and experimentally for aluminium alloy A356. The resulting microstructures of the cast billets obtained from the experiments are studied and characterized. Finally the experimental results are linked to the model predictions for establishing the relations involving interdependence of the stated key process parameters in determining the quality of the final cast products. This study is aimed towards providing the necessary guidelines for designing a cooling slope and optimizing the process parameters for desirable quality of the solidified product.