10.
The rheology of Al-30Si-5Cu and Al-30Si-5Cu-2Mg spray-formed alloys has been characterized after holding at various times
and temperatures, using semisolid rapid compression to obtain load-displacement curves. Microstructures were examined after
partial remelting and compression in an attempt to understand the flow behavior. The initial resistance to flow generally
increased with holding time at temperature. This increase was attributed to the increased strength of a three-dimensional
(3-D) solid silicon network present in these alloys in the semisolid state, with the initial resistance to flow smaller in
the magnesium-containing alloys. With increased temperature, the initial resistance decreased due to increased liquid content
and grain spheroidization. The viscosity
vs shear rate response was studied using the approach of Laxmanan and Flemings. The materials shear thinned rapidly during the
test conditions, in which the shear rate rapidly increased from approximately 2.5 to 92 s
−1. The results were fitted to a power-law model, and the viscosities showed a drop of approximately two to four orders of magnitude
when extrapolated to a shear rate of 1000 s
−1 (a typical value in actual component manufacture). The rapid compression test, which is close to conditions present in component
manufacture, was shown to have more in common with a shear rate jump experiment, rather than steady-state viscometry.
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