Experimental investigation of the transient and steady state rheological behaviour of Al–Si alloys in the mushy state

In order to properly model and control the semi-solid processing of metallic alloys, their thixotropic behaviour requires proper characterisation. In particular, the effects of shear rate, shear time, temperature and rest time on the rheology of such slurries needs to be understood and quantified. A purpose-built high temperature Searle rheometer was used to determine the rheological behaviour of aluminium alloy slurries at shear rates from 3.1 to 124.8 s−1, periods of shear of up to 60 min for each shear rate, and periods of rest (no stirring) of up to 60 min for Al–4wt.%Si and A356 alloys. Continuous cooling rheometry was used to determine the coherency point of the alloys. Isothermal fractions solid of 0.36 for Al–4%Si and 0.33 for A356 were investigated. Isothermal tests were used to follow the temporal evolution of viscosity, which was found to be significantly different for both alloys, particularly at low shear rates. Steady state viscosity values that were determined over a range of shear rates indicated severe pseudoplastic behaviour, as measured by a viscosity–shear rate power law index less than −1. This work confirms that this finding is an actual rheological feature and not an artefact of a particular measurement device. A study using shear rate jumps determined the isostructural behaviour of the alloys by discounting equipment inertial effects. It is shown that peak stress or apparent viscosity is a better indicator of slurry thixotropy than the hysteresis loop from shear ramping experiments, and the work also shows that the effect of agglomeration on fluidity is an important parameter to measure as it has consequences for thixoforming.