In this study, Al-Mg alloys were prepared by vacuum + argon-protected casting. The effects of Sc microalloying on the microstructure and mechanical properties of Al-Mg alloy were studied. The strengthening mechanism of Al-Mg alloy with Sc was discussed. The results show that the average grain size of as-cast Al-Mg alloy with Sc reaches 36.07 μm, which is 74.4% smaller than that of alloy 1 without refiner and 32.0% of alloy 2 with 0.15% Ti. The alloy with Sc has excellent comprehensive mechanical properties, with a tensile strength of 274 MPa and an elongation of 29.67%, and its tensile strength is 10.6% higher than alloy 1 and 7.9% higher than alloy 2. There exist two kinds of fine particles in as-cast Sc-containing Al-Mg alloy, nucleated particles Al₃Sc, and dispersed second-phase particles Al₃(Sc, Ti). The main strengthening mechanisms of the as-cast Al-Mg alloy with Sc reveal the solid solution strengthening of Mg and the fine-grain strengthening effect caused by Sc, accounting for 57.7% and 23.9% to strengthening contribution, respectively.

In this paper, the effect of adding the refiner Sc to the high Zn/Mg ratio 7xxx series aluminum alloy melt on the hot tearing performance, microstructure, and mechanical properties of the alloy is studied. The hot tearing performance test (CRC) method is used to evaluate the hot tearing performance of the alloy. The squeeze casting process was used to form solid cylindrical parts to analyze the structure and properties of the alloy. This study shows that the hot cracking sensitivity of the alloy after the addition of the refiner Sc is significantly reduced. The ingot grain size is significantly reduced, and the average grain size is reduced from about 86 μm to about 53 μm. While the mechanical properties are significantly improved, and the tensile strength reduced from 552 MPa is increased to 571 MPa, and the elongation rate is increased from 11% to 14%.

In this study, A390 alloy was prepared using the combined process of a water-cooled copper serpentine pouring channel (SPC) and strontium (Sr) modifier, in order to simultaneously refine primary silicon (Si) and modify eutectic silicon (Si). The nucleation and growth mechanisms of the Si phase were discussed by morphology analysis and non-isothermal analytical kinetics. The results indicate that the size of primary Si is refined to 25.2–28.5 µm and the morphology of eutectic Si is modified from acicular into fibrous. The serpentine pouring channel process stimulates primary Si nucleation due to chilling effect and has no influence on eutectic Si nucleation. Impacts of Sr-modifier on primary and eutectic Si are similar, including three aspects: (1) poisoning of the nucleation site; (2) decreasing the interface energy between Si phase and liquid; (3) raising the activation energy for diffusion across solid-liquid interface. The content of Sr determines which one of the three aspects mentioned above is the dominant factor to promote or restrain the nucleation and growth of the primary and eutectic Si in hypereutectic Al-Si alloy.

The hollow sand mold can affect the cooling of the casting during the solidification process. A chimney structure of a hollow sand mold that mainly consists of a two-layer shell with through channels was proposed. The design method was proposed for the chimney structure. Due to the chimney effect, cool air can enter the chimney from the bottom entrance, and hot air flows out from its top opening. Air transfers heat from the sand mold and forms a temperature gradient from bottom to top. A hollow sand mold with a chimney structure was applied to the wedge plate casting. During the solidification process, natural cooling and forced air cooling through open channels were applied. The effects of the chimney on the microstructure, mechanical properties, and residual stress of the castings under these two different cooling conditions were analyzed and compared with those of the casting in a dense mold. During the solidification stage of the castings, the chimney structure prolonged their solidification time. After solidification, the chimney structure under forced air condition increased the cooling rate of the castings by 61% and the temperature gradient along the vertical direction by a factor of three. The Si content in the Al matrix increased by 20.4%, and the tensile strength increased by 32.66%.

A semisolid slurry of 7075 aluminum alloy was prepared by means of a serpentine channel process (SCP) and rheo-diecasting. The influences of pouring temperature during slurry preparation, the injection pressure and die preheat temperature on the mechanical properties and microstructure of a rheo-diecast 7075 aluminum alloy were investigated. The results show that the as-cast strength and elongation of the tensile samples were 210–260 MPa and 0.2%–1.7%, respectively, with an injection pressure of 130 MPa, a pouring temperature of 700–720 °C, a preheat temperature of 280–350 °C, and a plunger speed of 0.5 ms⁻¹. The results also show that the aged strength and elongation of the tensile samples were 420–453 MPa and 1.0%–1.4%, respectively, when the alloy solution was treated at 470 °C for 12 h and aged at 120 °C for 24 h. The substantial shrinkage porosity in the 7075 aluminum alloy tensile samples was the main cause of low elongation.