Experiments on transient directional solidification were carried out to study the columnar to equiaxed transition (CET) in Al-7Si alloy without and with an alternating electric current pulse (AECP). Without AECP, the macrostructure consists of typical columnar and equiaxed zones, separated by a near horizontal plane. As the AECP is applied during solidification, an additional fine equiaxed zone (FEZ) occurs in the as-cast macrostructure. From measured temperature profiles, cooling rate and temperature gradient are determined. It is found that CET occurs for a critical value of the cooling rate, which is observed to be about 0.14 K·s⁻¹ in the present investigation. Furthermore, the macrostructural observation with mold for embedding the mesh plate demonstrates that the major factor responsible for the formation of fine equiaxed grains is the detachment of crystal nuclei from the upper contact surface and the lateral wall. The detachment is in turn ascribed to electric current-associated free energy change (ΔG_e)-induced the driving force F.

An experimental study with respect to the effect of an alternating electropulsing on grain refinement in pure aluminum was reported. The macrostructural observation with the mold preheated to different temperature and embedded the metal mesh indicated that the change of electric current-associated free energy related with the position of crystal nuclei (ΔG_em) and forced convection dominated the generation of fine equiaxed grains (FEG). Under electropulsing with 480 A, ΔG_em induced the dissociation of crystal nuclei from the upper interface of the electrode and the melt, leading to the generation of FEG. For a larger current intensity, FEG originated from the dissociation of crystal nuclei on the side wall besides the upper interface due to ΔG_em and the forced convection. Furthermore, the model coupling the dissociation of crystal nuclei and dendrite fragmentation due to the forced convection and the dissociation of crystal nuclei due to ΔG_em was presented to explain the formation mechanism of FEG in pure aluminum under electropulsing.