Materials Transactions, Vol. 43, No. 11 (2002) pp.

2913 to 2920

2002
c The Japan Institute of Metals
EXPRESS REGULAR ARTICLE

Effect of Degassing Treatment on the Quality of Al–7Si and A356 Melts ∗1

Li-Wu Huang1, ∗2 , Pi-Wein Wang1,∗2 , Teng-Shih Shih1, ∗3 and Jenq-Hwu Liou2
1
Department of Mechanical Engineering National Central University, Chung-Li, Taiwan 32054, R.O. China
2
Department of Mechanical Engineering Chien Kuo Institute of Technology, Changhua, Taiwan 500, R.O. China

In melting aluminum alloys, inclusion particles suspended in melt can be effectively reduced by floatation and/or sedimentation. Never-
theless, few researchers have focused on the effect of degassing bubbles on inclusion particles entrapped in the Al melt and the poured casting as
well. The degassed bubbles evolved from a diffuser, floated up and collapsed on free surface of the melt. After explosion, the splashed droplets
dropped on surface and then sank into melt following the movement of convection loop induced near the free surface of melt. Consequently,
after degassing treatment, Al–7Si melts increased the inclusion particle counts and foggy marks revealing on the section of chilled samples.
The A356.2 melts decreased the inclusion particle counts but increased the foggy marks on the poured chilled samples.

(Received August 1, 2002; Accepted September 26, 2002)

Keywords: oxide film, inclusion particle, foggy mark, convention loop

1. Introduction

Alloying element, such as Si and Mg, adding in aluminum

melt significantly increases the inclusion particles and devel-
ops a high pore density in solidified castings.1–4) Many meth-
ods have developed to assess the inclusion content for a given
melt. Weighting the filtered liquid metal in a closed cham-
ber has developed as PoDFA.5) The filter was sectioned and
then examined by a microscope to measure the quantity of in-
clusions. The Liquid Metal Cleanliness Analyzer (LiMCA)
instrument uses a DC current to monitor the quality of melt.6)
When inclusions entered the orifice of the analyzer, voltage
measured from the capillary unit would correspondingly drop.
Figure 1 shows the flow chart displaying the analytical
chemistry procedure termed as phenol filtration method.7, 8)
A piece of sample cut from casting was dissolved into a se-
lected chemical solution. After a period of time, the metal-
lic aluminum was entirely dissolved in the solution but the
inclusion left as residual. The whole solution was filtered
in order to capture the inclusion particles. These particles
were then removed to examine their morphologies and size,
and to identify their constituents by SEM equipped with an
EDAX. Qualiflash filtration technique,9) LAIS,10) a dual stage
ceramic foam filtration system11) or Chlorine fluxing12) meth-
ods can be another selection to reduce the inclusion content
in the melt. Most researchers believe that inclusions serve as
heterogeneous nucleation sites to develop pores in the cast- Fig. 1 Flow chart for filtration of particles existed in A356.2 sample via
ing. Consequently, the pores deteriorate the quality of the phenol filtration method.
casting.1–5, 7, 9, 10, 12)

2. Experimental Procedure
An induction furnace was used to melt different batches of
20–25 kg of aluminum alloys (3000 Hz, 150 kW) by using a
SiC-graphite-clay crucible. Master alloy of Al–50%Si was
added into the melt in order to bring silicon content to the
∗1 Partof this Paper was Presented at the 7th Asian Foundry Congress, on
Oct. 14, 2001, held in Taipei, Taiwan, R.O. China.
∗2 Graduate Students, National Central University.
∗3 Corresponding author: t330001@cc.ncu.edu.tw
desired levels. A high quality A356.2 ingot was melted to ob-
tain the chilled samples. After melting, all melts were held at
953 K and measured hydrogen content, 0.20–0.22 mL/100 g-
Al, by BOMEM ALSCAN model F-HMK 100D. This melt
held for 600 s and then poured to produce samples at 1033 K.
If degassing treatment was desired, melt held at 953 K, and
had degassed thoroughly with 2 L/min of nitrogen for 1800 s.
A diffuser, Fig. 2, generated clouds of fine gas bubbles float-
ing up from the bottom of the melt. After degassing treatment,
the hydrogen content was measured in the range of 0.09–
2914 L.-W. Huang, P.-W. Wang, T.-S. Shih and J.-H. Liou
Table 1 Chemical analyses of materials used in this study.
Main element Si (%)
Al–7%Si without degassing 7.06
Al–7%Si with degassing 6.85
A356.2 without degassing 6.75
A356.2 with degassing 6.81
A356.2 (low Sr) with degassing 7.04
Fig. 2 Diffuser shown in (a) three dimensions and (b) detailed scales.
0.12 mL/100 gAl. The melt further held at 953 K for 600 s
and then poured at 1033 K. A transferred ladle made of ce-
ramic fiber was used to pour the samples. The whole batch of
melt could pour six spoons; each spoon in series was coded
as corresponding to locations counting from top to bottom of
the melt in crucible. In other words, the samples from the
first spoon coming from top level of the melt and those from
the last spoon taking from bottom level of the melt. In addi-
tion to chill samples, each spoon also poured the keel block
castings, JIS H5202, at temperature about 1033 K. Chilled
samples were prepared in dimensions, 50 mm in diameter and
10 mm in thickness. After polishing, samples were analyzed
by spectrometer testing, Table 1.
After the spectrometer test, samples were polished again
and removed to measure inclusion particle counts via opti-
cal microscope equipped with image analyzer. The particle
counts were recorded. Each sample had been measured ten
times and the average of the total inclusion particle counts
was obtained.
After measuring the particle counts, chilled samples were
polished again and placed in an ultrasonic cleaner filled with
500 mL of tap water. These samples were then ultrasonic-
treated for 1800 s. Foggy marks would gradually show on
the polished surfaces of chilled samples during ultrasonic vi-
bration treatment. The morphology and area ratio of foggy
marks were measured and recorded. Each sample was mea-
Fe (%) Mg (%) Sr (ppm) Ti (%) Al (%)
0.09 0 — 0.01 Balance
0.11 0 — 0.01 Balance
0.07 0.34 214 0.13 Balance
0.12 0.33 165 0.11 Balance
0.13 0.35 <10 0.12 Balance
sured two sections and the average was counted as the area
ratio of foggy mark. A high-speed camera, 1000 pictures per
second, was also adopted to take photographs for showing
bubble explosion on free surface during water simulation.
3. Experimental Results
3.1 Oxide film and foggy mark
After the polished sample subjected to ultrasonic vibration
for a period of time, foggy marks show on its surface with
different shapes, reported by Shih et al.4) These foggy marks
formed due to eroded oxide film and/or cracking oxide film
on the surface of sample. These marks include foggy clouds,
strips or spots. Adding Si in the Al–Si alloy decreases the ex-
tent of foggy clouds and the length of foggy strip but increases
the number of foggy spots. Mg in the Al–Si–Mg alloy tends
to reduce the size of foggy clouds but greatly increases the
number of foggy spots. Reaction may occur in the Al–Si–Mg
melt to form spinel (MgO·Al2 O3 ) on the interface of oxide
film and in the melt, according to the description of Shih.4)
Figures 3(a) and (b) show the foggy marks on the surfaces
of chilled samples, after ultrasonic-vibration treatment. The
area ratios of foggy marks are 2.2% and 1.2% for Al–7Si and
A356.2 alloy respectively. This ratio is affected by the con-
stituent of melt and depends on sample taking from different
locations of melt as well. In fact, degassing treatment would
also affect the measured area ratio of foggy marks and will be
discussed latter.
The elastic modulus and hardness of oxide film and the
matrix of alloys (Al–7Si and A356.2) are quite different. If
oxide film existed on the polished surface, it may protrude ir-
regularly and microscopically out of sample surface, because
oxide film has a high elastic modulus than matrix. The pro-
truding points reduce the driving force for nucleating micro-
bubbles and consequently develop micro-jet impact on oxide
film. Micro-jet persistently impacts on the brittle oxide film
and explosion of micro-bubbles introduces the shock wave.13)
The micro-jet impact tends to crack the oxide film and to
erode the film gradually, as shown in Fig. 4 along with EDAX
analyses. This sample has been treated in the ultrasonic fre-
quency of 46 kHz for 2400 s. The polished surface demon-
strates foggy marks under optical, or visual, observation as
shown in Fig. 3.
3.2 Particles and pores
Inclusion particles readily exist in many active metal melts.
The oxide inclusion particles entrapped in Al alloy castings
significantly influence their surface appearance, mechanical
 Effect of Degassing Treatment on the Quality of Al–7Si and A356 Melts 2915

Measured at a white mark

Foggy marks

(a)

Foggy marks

Element Mass At
O K 22.63 51.47
MgK 0.81 1.21
Al K 25.02 33.74
Si K 3.03 3.92
AuK 47.56 8.79
CaK 0.96 0.87
Total 100.00 100.00
(b)
Fig. 4 SEM and EDAX analyses showing the morphology of foggy area;
Fig. 3 Chilled blocks of (a) Al–7Si and (b) A356.2 showing foggy area; sample from A356.2 melt and after ultrasonic vibration treatment with
after polished and ultrasonic vibration treatment with 46 kHz for 40 min. 46 kHz for 40 min.

properties and machining performance. Therefore, monitor-

ing and reducing the amounts of entrapped inclusions is a vital
issue in producing aluminum alloy castings. In order to iden-
tify the entrapped oxide particles, a thin sample was sliced
from chilled block and cooled by liquid nitrogen. This thin
sample was then fractured into two pieces and removed to ob-
serve their fractured surfaces via SEM. Figure 5 demonstrates
a feather-like oxide film, or particles, accompanied with a
pore. Apparently, this feather-like film serves as a heteroge-
neous nucleation site to form a pore. The surface of this pore
is bumpy and shows the morphology similar to Al dendrite.
This sample comes from Al–7Si melt and its constituents are
confirmed by the EDAX analyses. Figure 6 shows the frac-
tured surface of Al–7Si sample indicating the existence of in-
clusion particles.
Phenol filtration method7, 8) was adopted in this study to
collect inclusion particles. Particles from the filtrated residue
Fig. 5 SEM and EDAX analyses on a stringer-type oxide film accompanied
coated with gold and were examined by SEM. Figure 7 con- with a pore; Al–7Si sample after fractured.
firms that these particles are rich in alumina and some silica
and/or mullite. The analyzed carbon may come from the con-
tamination during extraction process. ing from top to bottom level of melt in the crucible.
Figure 8(a) shows the measured area ratio of foggy mark
3.3 Quality of Al–7Si alloy on chilled samples from different spoons, or corresponding
As mentioned in the experimental procedure, melt was to different levels in the melt. For the Al–7Si alloy without
poured into a spoon and then transferred to produce chilled degassing treatment, sample poured from near bottom level
samples and keel block (JIS H5202) castings. The whole shows a great deviation in the area ratio of foggy mark. After
batch of melt can poured 5–6 spoons. Samples produced degassing treatment, the Al–7Si sample from upper level of
from different spoons are coded as the locations correspond- melt contrarily illustrates a great deviation in the area ratio of
2916 L.-W. Huang, P.-W. Wang, T.-S. Shih and J.-H. Liou

Inclusion particles Al-7Si melts

with degassing (average:4.1 )

without degassing (average:2.2 )

7 7

Area Ratio of Foggy Mark ( )

6 6

5 5

4 4

3 3

2 2

1 1

0 0
Top Bottom
Corresponding Position in the Melt
(a)

Fig. 6 Oxide particles appeared on a fractured surface of a thin plate of

Al–7Si chilled specimen. Al-7Si melts

with degassing (average:245)

Measured at a black mark
without degassing (average:111)
350 350

300 300

Particle, N/count mm -2
250 250

200 200

150 150

100 100

50 50

0 0
Top Bottom
Corresponding Position in the Melt
(b)

Energy, E /keV
Element Mass At
Al K 36.17 47.10
OK 57.58 44.43
Si K 6.25 8.47
Total 100.00 100.00
Fig. 7 SEM and EDAX analyses of an inclusion particle; pure aluminum
sample after phenol filtration process.
foggy mark. This difference can definitely be attributed to the
influence of degassing treatment. If melt is without degassing
treatment and held for a period of time (more than 900 s), ox-
ide film may sink and cluster on the bottom of melt, since
the density of mullite (3Al2 O3 ·2SiO2 ) and aluminum liquid
is 2.8 × 103 and 2.3 × 103 kg/m3 respectively. Degassing
treatment produces stirring action and forms convection loop
in the melt. Oxide film floats up and moves following the
convection patterns developed in the melt. If holding time is
not long enough or the intensity of convection remains active,
oxide films are more likely to locate at the upper portion of
the melt since the difference in density of mullite and alu-
minum melt is small, Fig. 8(a). The samples poured from
melt with degassing treatment show a greater ratio of foggy
mark, 4.1% on the average of six samples, than those from
melt without degassing treatment, 2.2%. Regardless of de-
Fig. 8 Measured (a) ratio of foggy area and (b) particle count in Al–7Si
chilled blocks versus different samples corresponding to varying positions
in the crucible; melt with and without degassing treatment; melt degassing
treated by nitrogen (2 L/min, 1800 s) and holding at 993 K for 600 s.
gassing treatment, samples poured from near bottom level of
melt show higher particle counts (N /count·mm−2 , where N is
number), Fig. 8(b). This may result from fact that inclusion
particles sank in the molten melt during holding. Assuming
that the average moving velocity of the molten melt is small
during holding period and the particle is spherical, formula of
Vt = 2R (ρ9µs −ρ)g can be adopted in a creeping flow;14) where Vt
2
is the sinking speed of a mullite particle, m/s; ρs is the density
of mullite, 2.8 × 103 kg/m3 ; R is the radius of the mullite par-
ticle, 5×10−6 m; g is gravitational acceleration, 9.8 m/s2 . The
sinking speed of mullite particles is about 1.1 × 10−5 (m/s),
which is close to experimental value of 8.3 × 10−5 (m/s) from
that a particle sank and moved 50 mm in distance at 600 s in
creeping flow.
3.4 Quality of A356.2 alloy
Figures 9(a) and (b) show the relation of area ratio of foggy
mark and particle count of sample versus corresponding loca-
tion in the A356.2 melt. If the melt did not conduct degassing
treatment, samples poured from different levels remain a sta-
ble ratio of foggy mark, 1.2% on the average, and particle
count, 191 counts/mm2 on the average.
 Effect of Degassing Treatment on the Quality of Al–7Si and A356 Melts 2917

Table 2 The size distribution and inclusion particle counts existed in chill samples of A356.2 alloy with degassing treatment.

Composition A356.2 with high Sr

Particle size <2 µm 3–5 µm 6–10 µm 11–15 µm >15 µm Total
Count/mm2 (%) count (%) count (%) count % count % count % count %

Without degassing 78 40.84 73 38.22 31 16.23 7 3.66 2 1.05 191 100

treatment particle size below 10 µm contains 182 counts (95.29%)
42 35.59 41 34.75 22 18.64 8 6.78 5 4.24 118 100
Degassing treatment
particle size below 10 µm is 105 counts (88.98%)
Composition A356.2 with low Sr content
24 29.27 28 34.15 18 21.95 4 4.88 8 9.75 82 100
Degassing treatment
particle size below 10 µm contains 70 counts (85.37%)

A356.2 melts
samples with a high Sr content, 165 ppm, develop a greater
A356.2 (low Sr) with degassing (average:8.1 )
particle count in a greater deviation but a slightly lower ra-
A356.2 with degassing (average:6.7 )
tio of foggy mark than those with a low Sr content, less than
A356.2 without degassing (average:1.2 )

14 14
10 ppm.
Table 2 demonstrates the size distribution of inclusion par-
Area Ratio of Foggy Mark ( )

12 12
ticle existed in the A356.2 samples. These samples poured
10 10 from the melt without degassing treatment possessing a
8 8 greater number of inclusion particles than those poured af-
ter degassing treatment, 191 versus 118 count/mm2 . Particles
6 6
mostly have the size less than 10 µm, 90–95%. Decreasing
4 4 the Sr content in A356.2 melt can apparently reduce the par-
2 2 ticle count from 118 to 82 count/mm2 , especially for particle
0 0 size finer than 10 µm.
Top Bottom Summarily speaking, after degassing treatment, the inclu-
Corresponding Position in the Melt
(a) sion particle counts in A356.2 samples cut down to almost
half but those in Al–7Si samples increase more than two-fold,
as shown in Table 3. Most particle sizes are under 10 µm.
A356.2 melts Strontium is commonly added into A356.2 to modify the mor-
A356.2 without degassing (average:191)
phology of eutectic silicon. It increases the oxidation behav-
A356.2 with degassing (average:118)
ior of Al melt and inclusion particles in Al casting, reported
A356.2 (low Sr) with degassing (average:82)
by Emadi.1) This study confirms that adding Sr in A356 alloy
250 250 indeed increases the tendency for oxidation of A356.2 melt
and lifts up particle counts.
Particle, N/count mm -2

200 200

4. Discussion
150 150

4.1 Surface tension of Al alloy

100
50
0 0
Top
Corresponding Position in the Melt
(b)
Fig. 9 Measured (a) ratio of foggy area and (b) particle count in A356.2
chilled blocks versus different samples corresponding to varying positions
in the crucible; melt with and without degassing treatment; melt degassing
treated by nitrogen (2 L/min, 1800 s) and holding at 993 K for 600 s.
After degassing treatment, samples increase the ratio of
foggy mark but decrease the particle count with the depth in
the melt regardless of Sr content. In addition, samples poured
from different levels display a high degree of deviation either
in the ratio of foggy mark or the particle counts. The A356.2
100
The surface tension of pure aluminum (99.99%) is about
50 0.86 N/m. Adding 5%Si into aluminum melt slightly de-
creases its surface tension, 0.82 N/m, but alloying 5%Mg into
aluminum melt sharply cut the surface tension to 0.6 N/m.15)
Bottom
Adding Sr in A356.2 alloy not only decreases the surface ten-
sion of melt but also produces the Sr-base inclusion as Al–Si–
Sr and/or Sr–Al–O type compound.1, 16–18)
The surface of Al molten melt is normally covered with a
thin oxide film during melting and degassing treatment. If
the oxide film is perfectly composed of alumina, mullite or
spinel, these oxides provide a great strength, which can sup-
press degassed bubble floating and protruding out of free sur-
face. In fact, degassed bubbles float up, protrude out of free
surface and explode as can be seen in the experiment. This
indicates that the covered oxide films are possibly contami-
nated with impurities, such as Ca, Na or Cl and so on. This
2918 L.-W. Huang, P.-W. Wang, T.-S. Shih and J.-H. Liou

Table 3 The inclusion particle counts and their size distribution for samples of Al–7Si alloy with and without degassing treatment.

Composition Al–7%Si
Particle size <2 µm 3–5 µm 6–10 µm 11–15 µm >15 µm Total
Count/mm2 (%) count (%) count (%) count % count % count % count %

Without degassing 44 39.64 37 33.33 20 18.01 6 5.4 4 3.62 111 100

treatment particle size below 10 µm contains 101 counts (90.98%)
83 33.20 97 38.67 53 21.1 12 4.99 5 2.04 245 100
Degassing treatment
particle size below 10 µm contains 232 counts (92.97%)

Fig. 10 Phototgraphs taking from high-speed camera indicating the progressive sequence for forming a bubble on free surface of water
and its explosion, time step = (10−3 s).

greatly reduces the constraining force of covered oxide film, truding degassed bubbles. The thermal fluctuation of the melt
especially at high temperature. The electro-magnetic force can even be other possible factor to fracture the covered sur-
induced by the high frequency induction furnace may also be face oxide film, once the degassed bubble is approaching to
another driving force to break the covered oxide film for pro- the free surface. When a degassed bubble floats up near the
 Effect of Degassing Treatment on the Quality of Al–7Si and A356 Melts
free surface of melt, surface oxide fractures and bubble pro-
trudes out from the site of fracture. All of these sequences
occur in a short time. The new open surface is fresh without
oxide film developed and accumulated. The surface tension
of molten metal provides a constraining force for protruding
a degassed bubble and for remaining its shape on free surface,
once it protruded out of surface. Alloying elements influence
the surface tension of aluminum melt and the size of bubble
protruding out of free surface. If a molten melt possesses
a high surface tension, such as pure Al or Al–Si alloy, a de-
gassed bubble would protrude out of free surface significantly
causing big chunk of oxide films and/or great amounts of in-
clusion particles after degassed bubble exploded. For A356.2
melt, a degassed bubble can protrude less degree out of sur-
face of melt due to the addition of Mg, and therefore produce
a low amount of splashed droplets after explosion.
4.2 Bubble explosion in water simulation
A cylindrical tank, which made of transparent acrylic, was
filled with water in this study. The bottom plate of the tank
was drilled a small hole and sealed with silica gel. A bubble
was shot into water from the hole via a needlepoint of an in-
jector. A high-speed camera was used to record the dynamic
change of free surface of water during the period of bubble
approaching and explosion with time step of 10−3 s.19–23)
Figure 10 displays a series of photographs taking from ex-
periment. A small amount of air injected into the bottom of
tank will instantly form bubble floating up to free surface of
water. When the bubble reaches at the free surface, it remains
stable in its shape for a short period of time, as shown in
Figure 10(a). The bubble explodes from top area and then
collapses, as shown from Figs. 10(b) to (d). There are several
shinning spots shown on Figs. 10(d) and (e). These shinning
spot are more likely the splashing water droplets produced
from the collapsed bubble.
Simply, ignore the effect of convection loop induced by
floating bubbles and its dynamic interaction on the size and
shape of bubble. Decreasing surface tension of solution re-
duces the constraining force for remaining bubble on free sur-
face causing an early explosion. Therefore the size of bubble
protruding out of free surface is decreased; in other words,
the bubble contour protruding out of free surface is decreased.
Adding magnesium in Al–Si melt greatly lowers the surface
tension of the melt. Therefore, the stable size of bubble pro-
truding out of free surface of A356.2 melt is correspondingly
decreased and most degassed bubbles develop early explo-
sion during degassing treatment. Fewer or finer droplets can
be produced from each bubble explosion comparing with the
case of Al–7Si melt. Droplets fall down on free surface and
sinks into melt. The droplets or piece of oxide films move into
the melt following the movement of convection loop within
melt, as schematically illustrated in Fig. 11. Theoretical anal-
yses for showing convection loops in the melt and downward
air stream above the free surface refer to Appendix 1. In this
analysis, the K -ε turbulence model was used and the comput-
ing domain was set to be 40000 grids.
4.3 Clustering of oxide film and inclusion particles
The inclusion particles or oxide film in Al–7Si melt is
mainly mullite, which is stable in the melt. In the A356.2
2919
Fig. 11 Schematic illustration showing the sequence of degassed bubble
floats up to the free surface of melt while the air stream flows downward
and convection loops in the melt are induced.
melt, different oxide particles of SiO2 , MgO and spinel ac-
companied with alumina may be possibly existed after de-
gassing treatment. These oxide particles in the A356.2 melt
may react with alumina to form pyrope, Mg3 Al2 Si3 O12 with
3.56 × 103 kg/m3 in density, via the stirring action during de-
gassing treatment. Clustering of particles with oxide film in-
crease the number of foggy spots in the previous study,4) and
the area ratio of foggy mark in the A356.2 sample after de-
gassing treatment, Fig. 9(a). The alumina, spinel and pyrope
are with a greater density than liquid aluminum. After de-
gassing treatment, the A356.2 samples display high area ra-
tios of foggy marks distributed at location near bottom level
of melt, as illustrated in Fig. 9(a).
4.4 Effect of inclusion particles on fatigue of Al–7Si cast-
ings
In the experiment, molten metal poured into permanent
mold, JIS H5202. The degassing-treated Al–7Si samples are
prepared for fatigue test. The samples subjected to a rotat-
ing and bending test with stress amplitude of 80 MPa. At
this stress amplitude, the cycles to failure of specimens were
recorded. These samples were then sectioned to assess the in-
clusion particle counts after polishing. Figure 12 displays the
relation of inclusion particles and cycles to failure of each
sample. The inclusion particle counts are 187 count/mm2
for specimen 1 developing 2.15 × 105 life cycles. Speci-
men 5 possesses particle count 49 count/mm2 and performs
3.11 × 105 life cycles. All five specimens have above 95%
of particles with size less than 10 µm. The inclusion particles
existed in the matrix of tested bars may serve as the initiator
for forming and growing micro-cracks. This shortens the in-
cubation period of crack initiation and accelerates the crack
propagation during constructing a crack. Consequently, fa-
tigue life is decreased, if the matrix of alloy casting possesses
significantly high particle counts.
5. Summary
After degassing, the Al–7Si melts increased inclusion par-
ticle counts. The inclusion particles usually contained Al, Si
and O elements and formed the compound of mullite in Al–
7Si melt and casting as well. Degassing treatment produces
2920 L.-W. Huang, P.-W. Wang, T.-S. Shih and J.-H. Liou

250 250 (1999) 49–65.

inclusion particle, count/mm 2 Inclusion Particle 10) D. Sampath, P. G. J. Flick, J. Pool, W. Boender and W. van Rijswijk: The
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below 10 um 200 Minerals, Metals & Materials Society, Light Metals (1996) 817–821.
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& Materials Society, Light Metals (1996) 845–855.
150 150
121 12) C. Nyahumwa, N. R. Green and J. Campbell: AFS Trans. 106 (1998)
95.04 215–224.
100 75 74 100 13) J.-J. Chen, L.-W. Huang and T.-S. Shih: Mater. Trans. (JIM), 2002, to
98.67 90.54
49 be submitted.
100 14) G. H. Geiger and D. R. Poirier: Transport Phenomena in Metallurgy,
50 50
(Addison-Wesley Publishing Company, 1980) pp. 68–71.
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0 0 pp. 35–50.
failure to cycles: 215100 264800 272800 275800 310900
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1 2 3 4 5
erties of Minerals. (1979) pp. 152–174.
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size out of free surface in Al–7Si melt than in A356.2 melt.
This produced a great amount of splashed droplets in Al–7Si
Appendix
melt after bubbles explosion.
After degassing treatment, the A356.2 samples increased
(1) Using the Fluent 5.5 edition to solve the equations in-
the ratio of foggy marks but decreased the particle counts.
cluding Continuity equation and Momentum equation
The splashed droplets of A356.2 melt formed oxide parti-
under K -
Turbulence Model.
cles of alumina, mullite, and/or spinel. Clustering of particles
(2) Using VOF (Volume of fraction) model to determine the
with oxide film led to form pyrope during degassing. This
convection term of gas-liquid interface under processing
increased the number of foggy spots and area ratio but de-
of Second order upwind.
creased the particle counts. Decreasing Sr content in A356.2
(3) Using explicit term of time (∆t = 5 × 10−5 s), Solv-
melt significantly decreased the particle counts.
ing the transient convection field by taking the numeri-
cal method of PISO (Pressure-implicit with splitting of
Acknowledgements
operators).
The authors greatly appreciate the National Science Coun-
cil, ROC, for financial support of this research, NSC 91-2216-
E-008-006.

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