Aluminum segregation in ZA27 rheocast alloy

Aluminum segregation in zinc alloys is a well-known problem during melting and casting. In molten Zn alloys, in fact, Al tends to float on the surface of the bath because of its lower density than zinc. The same problem also occurs during casting solidification, causing chemical gradients along part thickness and soundness problems. As a consequence, the use of high aluminum content zinc alloys, such as ZA27, can be limited. In this paper the effectiveness of rheocasting method on decreasing Al-segregation phenomenon in ZA27 was investigated. The slurry was obtained by using the ultrasound technique, starting from the fully liquid down to different solid fraction percentages. The metal was then cast into a permanent steel mold. The produced samples were completely characterized by metallographic analysis (optical and scanning electron microscope), to assess the microstructure modification induced by the treatment. Hardness tests were also performed to evaluate mechanical properties. For comparison, the same tests were performed on conventionally cast samples. The analyses show that the use of a semisolid alloy increases the homogeneity of the part in terms of hardness, chemical composition and microstructure; furthermore casting’s shrinkage porosity is significantly reduced.