MCAST (melt conditioning by advanced shear technology) is a novel processing technology developed recently for conditioning liquid metal prior to solidification processing. The MCAST process uses a twin screw mechanism to impose a high shear rate and a high intensity of turbulence on the liquid metal, so that the conditioned liquid metal has uniform temperature, uniform chemical composition and well-dispersed and completely wetted oxide particles with a fine size and a narrow size distribution. The microstructural refinement is achieved through an enhanced heterogeneous nucleation rate and an increased nuclei survival rate during the subsequent solidification processing. In this paper we present the MCAST process and its applications for microstructural refinement in both shape casting and continuous casting of light alloys.

This study reports the current status of grain refinement of copper accompanied in particular by a critical appraisal of grain refinement of phosphorus-deoxidized, high residual P (DHP) copper microalloyed with 150 ppm Ag. Some deviations exist in terms of the growth restriction factor (Q) framework, on the basis of empirical evidence reported in the literature for grain size measurements of copper with individual additions of 0.05, 0.1, and 0.5 wt pct of Mo, In, Sn, Bi, Sb, Pb, and Se, cast under a protective atmosphere of pure Ar and water quenching. The columnar-to-equiaxed transition (CET) has been observed in copper, with an individual addition of 0.4B and with combined additions of 0.4Zr-0.04P and 0.4Zr-0.04P-0.015Ag and, in a previous study, with combined additions of 0.1Ag-0.069P (in wt pct). CETs in these B- and Zr-treated casts have been ascribed to changes in the morphology and chemistry of particles, concurrently in association with free solute type and availability. No further grain-refining action was observed due to microalloying additions of B, Mg, Ca, Zr, Ti, Mn, In, Fe, and Zn (~0.1 wt pct) with respect to DHP-Cu microalloyed with Ag, and therefore are no longer relevant for the casting conditions studied. The critical microalloying element for grain size control in deoxidized copper and in particular DHP-Cu is Ag.