Melt Flow and Grain Refinement in Al-Si Alloys Solidified under the Influence of Applied Electric Currents

The solidification of Al-7wt.% Si alloys under the influence of electric current pulses (ECP) through two parallel electrodes at the melt surface is investigated. An effective grain refinement was found if the ECP is applied during the initial solidification period (nucleation and recalescence). The grain size can be gradually reduced, which is likely due to the remelting process of high-order dendrite arms in the mushy zone driven by solute fluctuation and promoted by thermal fluctuation. This fragmentation process is mainly driven by electromagnetically forced convection. The grain refinement does not require the formation of nuclei from a solidified shell near the electrodes, which would result in a grain rain inside the sample.