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Review of Grain Refinement of Cast Metals Through Inoculation: Theories and Developments

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Abstract

The inoculation method of grain refinement is widely used in research and industry. Because of its commercial and engineering importance, extensive research on the mechanisms/theories of grain refinement and development of effective grain refiners for diverse cast metals/alloys has been conducted. In 1999, Easton and St. John reviewed the mechanisms of grain refinement of cast Al alloys. Since then, grain refinement in alloys of Al, Mg, Fe, Ti, Cu, and Zn has evolved a lot. However, there is still no full consensus on the mechanisms/theories of grain refinement. Moreover, some new grain refiners developed based on the theories do not ensure efficient grain refinement. Thus, the factors that contribute to grain refinement are still not fully understood. Clarification of the prerequisite issues that occur in grain refinement is required using recent theories. This review covers multiple metals/alloys and developments in grain refinement from the last twenty years. The characteristics of effective grain refiners are considered from four perspectives: effective particle/matrix wetting configuration, sufficiently powerful segregating elements, preferential crystallographic matching, and geometrical features of effective nucleants. Then, recent mechanisms/theories on the grain refinement of cast metals/alloys are reviewed, including the peritectic-related, hypernucleation, inert nucleant, and constitutional supercooling-driven theories. Further, developments of deterministic and probabilistic modeling and nucleation crystallography in the grain refinement of cast metals are reviewed. Finally, the latest progress in the grain refinement of cast Zn and its alloys is described, and future work on grain refinement is summarized.

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Acknowledgments

Sincere appreciation is expressed to Professor Mingxing Zhang, A/Professor John A. Taylor, and Emeritus Professor David StJohn at The University of Queensland (UQ), Dr. Dong Qiu and Professor Mark A. Easton at RMIT University, and Dr. Feng Wang at Brunel University London for their engaged discussion when I studied at UQ. This work is supported by National Natural Science Foundation of China (Grant No. 51605496), and also financially funded by the State Key Laboratory of High Performance Complex Manufacturing (No. ZZYJKT2016-03). Zhilin Liu would like to acknowledge Jing Ouyang (his wife) for her love, understanding and support during this work.

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  1. College of Mechanical and Electrical Engineering, Central South University, Changsha, 410083, People’s Republic of China

    Zhilin Liu

  2. IMDEA Materials Institute, C/Eric Kandel 2, 28906, Getafe, Madrid, Spain

    Zhilin Liu

  3. School of Mechanical and Mining Engineering, The University of Queensland, Brisbane, QLD, 4072, Australia

    Zhilin Liu

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Liu, Z. Review of Grain Refinement of Cast Metals Through Inoculation: Theories and Developments. Metall Mater Trans A 48, 4755–4776 (2017). https://doi.org/10.1007/s11661-017-4275-7

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