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Coarse microstructures and severe macrosegregation always occur in large-sized billets prepared by normal direct chill casting, and cannot be eliminated during subsequent deformation or high temperature annealing. This study proposes a new melt treatment method coupled to annular electromagnetic stirring and intercooling, and applies it to direct chill casting of large-sized 2219 aluminum alloy billets. Compared to the normal direct chill casting, the microstructure and second phase were refined and homogenized, and the macrosegregation of Cu was alleviated. Accordingly, the average tensile and yield strengths, elongation and hardness were significantly improved and remained relatively stable at different positions on the billet. Tensile fracture tests showed that annular electromagnetic stirring coupled with intercooling decreases the amount of porosity in the structure.

international journal of materials research

Effect of coupled annular electromagnetic stirring and intercooling on the microstructures, macrosegregation and properties of large-sized 2219 aluminum alloy billets