The distribution homogeneity of grain size affects the fluidity of the semi-solid slurry, which in turn affects the properties of the casting. One key factor affecting grain size uniformity resides in the nucleation number, which has been studied thoroughly, while the other factor is temperature gradient which has not been investigated yet. In this study, the microstructure evolutions under certain temperature gradients are investigated by experiment and simulation using a two-dimensional quantitative phase-field (PF) model. A parallel and adaptive mesh refinement algorithm is adopted to solve the nonlinear phase-field equations. The results indicate that temperature gradient can affect the size distribution of microstructure in the semi-solid slurry prepared by the SEED process. A higher temperature gradient (in the range of 0.230~0.657 °C/mm) along the radial direction is beneficial to the homogeneity of the grain size in a slurry.

The microstructure and mechanical properties of semisolid rheo-diecasting Al-xZn-2Mg-1.5Cu alloys with different Zn contents were investigated by scanning electron microscopy (SEM), X-ray diffraction (XRD), hardness testing (HV) and room temperature tensile testing. Results show that the as-cast microstructure mainly consists of spherical α-Al and Mg(Al, Cu, Zn)₂ phases. Furthermore, a small amounts of Al₇Cu₂Fe phases were also detected along the grain boundary. Increasing the Zn contents from 8–12%, the volume fraction of the Mg(Al, Cu, Zn)₂ phases increases from 4.9–7.4%. After solution heat treatment at 470 °C for 8 h, most of the Mg(Al, Cu, Zn)₂ dissolves into the α-Al matrix, while the Al₇Cu₂Fe phase keeps with remains. The yield strength linearly increases from 482 ± 5 MPa of 8% Zn to 529 ± 5 MPa of 12% Zn. While, the ultimate strength of 10% Zn is 584 ± 2 MPa, which is higher than that of the other two alloys. Moreover, the average elongation dramatically decreases from 13% for the 8% Zn alloy to 2% for the 12% Zn alloy.

This study aims to bridge the critical knowledge gap in understanding the dynamic microstructural evolution during high-solid-fraction semi-solid rheo-die casting process, including slurry preparation (0.1–0.3 K/s) and rheo-die casting (10–150 K/s). A novel phase-field model coupling continuous cooling with explicit nucleation was developed, enabling the dynamic simulation of continuous solidification microstructure evolution, considering two-stage cooling rate transition characteristics. Integrated the Swirled Enthalpy Equilibration Device (SEED) slurry preparation and graded-cooling mold experiments established variable cooling rate and solid fraction conditions for quantitative analysis of α-Al morphological evolution during rheo-die casting solidification. Through experimental and simulation investigations of the Al-7Si alloy, it is concluded that during Stage I slurry preparation, the primary α₁-Al phase coarsened due to Ostwald ripening. In Stage II rheo-die casting, primary α₁-Al undergoes continued growth under a moderate cooling rate (15 K/s). Meanwhile, secondary α₂-Al formation exhibits a cooling-rate and solid fraction dependence: a high cooling rate (150 K/s) promotes explosive nucleation with the volume fraction decreasing from 4.78% to 0.33% as the solid fraction rises, whereas a mid-cooling rate (15 K/s) substantially suppresses its formation. Mechanistically, a high cooling rate promotes solute trapping, which intensifies constitutional undercooling, thereby elevating both the nucleation and growth driving forces to facilitate the formation of secondary α₂-Al, whereas higher solid fractions restrict secondary phase formation by narrowing the solidification windows from 22 °C to 7 °C.