Semi solid metal processing: The fraction solid dilemma

One of the most challenging aspects in semi solid metal (SSM) processing is to determine the actual volume fraction of the solid at the processing temperature. The fraction has great impact on the SSM slurry viscosity and the subsequent filling of the mold in the casting stage. Three methods, namely quantitative metallography, thermodynamic calculation, and thermal analysis are employed to investigate and clarify the contradictory open literature reports about the real value of the volume fraction of primary particles. It is reported that the discrepancies between the results obtained by different methods are caused mainly by variations in cooling rates and by coarsening of the primaries during the quenching process.