Effects of Solidification Techniques on Cast Quality: A Systematic Review and Network Mapping
References
- Stefanescu DM, Davis JR, Destefani JD. Metals handbook. Casting. Metals Park (OH): ASM International. 1988; 15: 937.
- Mohanty UK, Sarangi H. Casting processes and modelling of metallic materials. London: IntechOpen; 2020; 19–40. https://doi.org/10.5772/intechopen.91879
- Minkoff I. Materials processes: a short introduction. Berlin: Springer. 1992; 1–31.
- Jorstad JL. In: ASM handbook. Vol. 15, Casting. Materials Park (OH): ASM International; 2008.
- Karimi P, Sadeghi E, Ålgårdh J, Keshavarzkermani A, Esmaeilizadeh R, Toyserkani E et al. A new framework for in‑situ monitoring in powder bed fusion. Addit Manuf. 2021;46:102086. https://doi.org/10.1016/j.addma.2021.102086
- Bolzoni L, Xia M, Babu NH. Refinement of cast grain structure of commercial purity aluminium induced by Al–Ti, Al–B and Al–Ti–B master alloys. Sci Rep. 2016;6:39554. https://doi.org/10.1038/srep39554
- Katgerman L. Solidification and casting of aluminium alloys. Mater Today. 2011;14(10):502–8. https://doi.org/10.1016/S1369-7021(11)70219-5
- Nakajima H. Fabrication, properties and application of porous metals with directional pores. Prog Mater Sci. 2007;52(7):1091–173. https://doi.org/10.1016/j.pmatsci.2006.10.001
- Rajagopal V, Venkatesan SP, Goh M. Simulation‑based optimisation of casting supply chain. Comput Ind Eng. 2017;113:646–82. https://doi.org/10.1016/j.cie.2017.09.027
- Visik EM, Gerasimov VV. Improvement of casting quality by modification. Metallurgist. 2014;57:1036–42. https://doi.org/10.1007/s11015-014-9930-4
- Wang F, Ma D, Zhang J, Liu L, Hong J, Bogner S, et al. Directional solidification of intermetallic alloys. J Cryst Growth. 2014;389:47–54. https://doi.org/10.1016/j.jcrysgro.2013.11.009
- Ma D. Solidification of intermetallic alloys: fundamentals and applications. Front Mech Eng. 2018;13(1):3–16. https://doi.org/10.1007/s11465-018-0483-z
- Balter M, Neumann C, Bräuer D, Dreißigacker C, Steinbach S. High‑speed X‑ray imaging for solidification. Rev Sci Instrum. 2019;90:125117. https://doi.org/10.1063/1.5128736
- Zhang H, Xu Q. Cellular and dendritic growth in solidification. Phys Status Solidi B. 2017;254(10):1700252. https://doi.org/10.1002/pssb.201700252
- Ghedjati K, Fleury E, Hamani MS, Benchiheub M, Bouacha K, Bolle B. Grain refinement in aluminium alloys. Int J Miner Metall Mater. 2015;22:509–15. https://doi.org/10.1007/s12613-015-1118-0
- Ma DX, Zhou B, Bührig‑Polaczek A. Effect of process parameters on directional solidification. Adv Mater Res. 2011;278:428–33. https://doi.org/10.4028/www.scientific.net/AMR.278.428
- Liu Y, Wang F, Ma D, Yang Q, Xu W, Zhao Y, et al. Directional solidification of Ni‑base superalloys under high thermal gradients. Acta Mater. 2024;266:119702. https://doi.org/10.1016/j.actamat.2023.119702
- Zhang H, Xu Q, Liu B. Effect of withdrawal rate on microstructure in directionally solidified alloys. Materials (Basel). 2014;7(3):1625–39. https://doi.org/10.3390/ma7031625
- Saad A, Gandin CA, Bellet M, Shevchenko N, Eckert S. In‑situ observation of columnar‑equiaxed transition. Metall Mater Trans A. 2015;46:4886–97. https://doi.org/10.1007/s11661-015-3065-5
- Wang F, Ma D, Bogner S, Bührig‑Polaczek A. Influence of mould design on directional solidification. Metall Mater Trans A. 2016;47:2376–86. https://doi.org/10.1007/s11661-016-3410-2
- Costa M, Souza F, Magno I, Loayza C, Nascimento J, Barros A, et al. Microstructure of Al–Si alloys produced by conventional casting. Medžiagotyra. 2017;23(2):124–8. https://doi.org/10.5755/j01.ms.23.2.15768
- Lian Y, Li D, Zhang K. Solidification behaviour of aluminium alloys under different cooling rates. Mater Trans. 2016; 57(10):1671–9. https://doi.org/10.2320/matertrans.M2016157
- Zhang H, Xu Q. Numerical simulation of dendritic growth. J Mater Process Technol. 2016;238:132–41. https://doi.org/10.1016/j.jmatprotec.2016.07.016
- Wang J, Zheng L, Kang J, Hu Y. Effect of cooling rate on microstructure and properties of Al–Si alloys. Materials (Basel). 2020;13(9):2197. https://doi.org/10.3390/ma13092197
- Durga A, Dai H, Huang S, Spinelli I, Yuan L. Columnar‑to‑equiaxed transition in cast alloys. JOM. 2020;72:1785–93. https://doi.org/10.1007/s11837-020-04157-0
- Kurz W, Rappaz M, Trivedi R. Solidification microstructures: past, present and future. Int Mater Rev. 2021;66(1):30–76. https://doi.org/10.1080/09506608.2020.1835793
- Huang W, Wang L. Numerical modelling of solidification structures. Sci China Technol Sci. 2012;55:377–86. https://doi.org/10.1007/s11431-011-4655-5
- Kim SW, Lee YS, Lee JW, Lim SS, Jung TK, Hyun SK. Effect of cooling conditions on casting defects. Met Mater Int. 2020;26:660–7. https://doi.org/10.1007/s12540-019-00394-8
- Li F, Wang D, Jiang Y, Yang L, Zhao Y, Zhang X. Optimisation of casting process parameters using numerical simulation. Int J Adv Manuf Technol. 2019;104:3065–72. https://doi.org/10.1007/s00170-019-04050-4
- Yang J, Wang H, Wu Y, Wang X, Hu R. Defect formation in directionally solidified alloys. Adv Eng Mater. 2018;20(2):1700526. https://doi.org/10.1002/adem.201700526
- Borsato T, Ferro P, Berto F, Carollo C. Fatigue behaviour of cast aluminium alloys. Eng Fail Anal. 2017;79:902–12. https://doi.org/10.1016/j.engfailanal.2017.04.013
- Borsato T, Ferro P, Berto F, Carollo C. Influence of defects on fatigue life in castings. Int J Fatigue. 2017;102:221–7. https://doi.org/10.1016/j.ijfatigue.2017.05.027
- Rashidi MM, Idris MH. Evaluation of casting defects and mechanical properties in Al alloys. Mater Des. 2013;51:861–9. https://doi.org/10.1016/j.matdes.2013.04.084
- Alabbasian F, Boutorabi SMA, Kheirandish S. Effect of melt treatment on microstructure of cast aluminium alloys. Mater Sci Eng A. 2016;651: 467–73. https://doi.org/10.1016/j.msea.2015.10.115
- Rathi SK, Sharma A, Di Sabatino M. Analysis of porosity in cast aluminium alloys. Eng Fail Anal. 2017;79:592–605. https://doi.org/10.1016/j.engfailanal.2017.05.023
- Pongen R, Birru AK, Parthiban P. Influence of melt stirring on casting quality. Results Phys. 2019;13:102105. https://doi.org/10.1016/j.rinp.2019.102105
- Santhosh AJ, Lakshmanan AR. Effect of grain refiners on mechanical properties of cast Al alloys. China Foundry. 2016;13:352–60. https://doi.org/10.1007/s41230-016-5117-0
- Bo X, Li YD, Ying M, Chen TJ, Yuan H. Effect of rare earth additions on microstructure of Al alloys. Trans Nonferrous Met Soc China. 2010;20(9):1622–9. https://doi.org/10.1016/S1003-6326(09)60376-8
- Xing B, Hao Y, Li YD, Ma Y, Chen TJ. Grain refinement of Al–Si alloys by rare earth additions. Trans Nonferrous Met Soc China. 2013;23(3):567–75. https://doi.org/10.1016/S1003-6326(13)62403-4
- Li M, Li Y, Zhou H. Microstructure and mechanical properties of ZA27 alloy rheo-diecasting process fabricated by self-inoculation method. Mater Res. 2020;23:e20200101.
- Li M, Li YD, Huang XF, Cao C, Ma Y. Solidification behavior and rheodiecasting microstructure of A356 aluminum alloy prepared by self-inoculation method. China Foundry. 2017;14:1–9.
- Ming LI, ZHENG HQ, HUANG XF, Ying MA. Solidification behavior of 6061 wrought aluminum alloy during rheo-diecasting process with self-inoculation method. Transactions of Nonferrous Metals Society of China. 2018;28(5):879-89. https://doi.org/10.1016/S1003-6326(18)64721-1
- Tan Q, Zhang J, Sun Q, Fan Z, Li G, Yin Y, Liu Y, Zhang MX. Inoculation treatment of an additively manufactured 2024 aluminium alloy with titanium nanoparticles. Acta Mater. 2020;196:1–16.
- Fay A. Influence of inoculation on cast iron machinability: case studies. China Foundry. 2020;17(2):150–157.
- Komarov OS, Volosatikov VI, Provorova IB. Complex inoculation of steel. Metal Sci Heat Treat. 2013;55(3):163–166.
- Sun ZY, Liang Y, Yu LF, Shi ZY. Effects on the as-cast structure of 7075 aluminum alloy by treating with electrical pulse inoculation. Adv Mater Res. 2012;535:954–958.
- Kim KH, Bae CM. Reduction of segregation during casting of 100Cr6 bearing steel by cerium inoculation. Metals Mater Int. 2013;19:371–375.
- Samaddar S, Das T, Chowdhury AK, Singh M. Manufacturing of engineering components with austempered ductile iron – a review. Mater Today Proc. 2018;5(11):25615–25624.
- Sahoo PK, Pattnaik S, Sutar MK. A state-of-the-art review on manufacturing and additive influences on sand-cast components. Arab J Sci Eng. 2019;44(12):9805–9835.
- Fraś E, Lopez HF, Kawalec M, Gorny M. Role of alloying additions in the solidification kinetics and resultant chilling tendency and chill of cast iron. Metals. 2015;5(1):256–288.
- Kilbride P, Morris GJ, Milne S, Fuller B, Skepper J, Selden C. A scale down process for the development of large volume cryopreservation. Cryobiology. 2014;69(3):367–375.
- Mackay RI, Sokolowski JH. Effect of Si and Cu concentrations and solidification rate on soundness in casting structure in Al–Si–Cu alloys. Int J Cast Met Res. 2010;23(1):7–22.
- Wang YZ, Ding HS, Chen RR, Guo JJ, Fu HZ, Lü JP. A high-Nb TiAl alloy with highly refined microstructure and excellent mechanical properties fabricated by electromagnetic continuous casting. China Foundry. 2016;13:342–345.
- Choudhari CM, Narkhede BE, Mahajan SK. Methoding and simulation of LM6 sand casting for defect minimization with its experimental validation. Procedia Eng. 2014;97:1145–1154.
- Meena A, El Mansori M. Correlative thermal methodology for castability simulation of ductile iron in ADI production. J Mater Process Technol. 2012;212(11):2484–2495.
- Ayar MS, Ayar VS, George PM. Simulation and experimental validation for defect reduction in geometry varied aluminium plates casted using sand casting. Mater Today Proc. 2020;27:1422–1430.
- Saravanan VS, Palanisamy C, Mohanraj M, Shah J, Bhero S. A study on relationship between casting geometric modulus and feeding distance of ductile iron bar-shaped castings. Int J Metalcast. 2016;10:477–482.
- Yigezu BS, Jha PK, Mahapatra MM. The key attributes of synthesizing ceramic particulate reinforced Al-based matrix composites through stir casting process: a review. Mater Manuf Process. 2013;28(9):969–979.
- An H, Bao Y, Wang M, Yang Q, Huang Y. Improvement of centre segregation in continuous casting bloom and the resulting carbide homogeneity in bearing steel GCr15. Ironmak Steelmak. 2019.
- Mullis AM. The origins of spontaneous grain refinement in deeply undercooled metallic melts. Metals. 2014;4(2):155–167.
- Herlach DM. Non-equilibrium solidification of undercooled metallic melts. Mater Sci Eng R Rep. 1994;12(4–5):177–272.
- Lavernia EJ, Srivatsan TS. The rapid solidification processing of materials: science, principles, technology, advances, and applications. J Mater Sci. 2010;45:287–325.
- Zhai Y, Pan K, Wu D. Acquiring high-quality oil casing steel 26CrMoVTiB under optimal continuous casting process conditions. Metals. 2019;9(9):993.
- Wan J, Ruan H, Shi S. Excellent combination of strength and ductility in 15Cr–2Ni duplex stainless steel based on ultrafine-grained austenite phase. Mater Sci Eng A. 2017;690:96–103.
- Wang H, Zhou L, Zhang Y, Cai Y, Zhang J. Effects of twin-roll casting process parameters on the microstructure and sheet metal forming behavior of 7050 aluminum alloy. J Mater Process Technol. 2016;233:186–191.
- Drozdenko D, Yamasaki M, Mathis K, Dobroň P, Lukáč P, Kizu N, Inoue SI, Kawamura Y. Optimization of mechanical properties of dilute Mg–Zn–Y alloys prepared by rapid solidification. Mater Des. 2019;181:107984.
- Jiang WM, Fan ZT, Liu DJ, Liao DF, Zhao Z, Dong XP, Wu HB. Influence of process parameters on filling ability of A356 aluminium alloy in expendable pattern shell casting with vacuum and low pressure. Int J Cast Met Res. 2012;25(1):47–52.
- Delshad Khatibi P, Phillion AB, Henein H. Microstructural investigation of D2 tool steel during rapid solidification. Powder Metall. 2014;57(1):70–78.
- Chang QM, Chen CJ, Zhang SC, Schwam D, Wallace JF. Effects of process parameters on quality of squeeze casting A356 alloy. Int J Cast Met Res. 2010;23(1):30–36.
- He C, Li Y, Li J, Xu G, Wang Z, Wu D. Effect of electromagnetic fields on microstructure and mechanical properties of sub-rapid solidification-processed Al–Mg–Si alloy during twin-roll casting. Mater Sci Eng A. 2019;766:138328.
- Kanthavel K, Arunkumar K, Vivek S. Investigation of chill performance in steel casting process using response surface methodology. Procedia Eng. 2014;97:329–337.
- Zhang HJ, Zhang DF, Ma CH, Guo SF. Improving mechanical properties and corrosion resistance of Mg–6Zn–Mn magnesium alloy by rapid solidification. Mater Lett. 2013;92:45–48.
- Öztürk S, Sünbül SE, Kürşat İCİ. Effects of melt spinning process parameters and wheel surface quality on production of 6060 aluminum alloy powders and ribbons. Trans Nonferrous Met Soc China. 2020;30(5):1169–1182.
- Sahoo S, Kumar A, Dhindaw BK, Ghosh S. Modeling and experimental validation of rapid cooling and solidification during high-speed twin-roll strip casting of Al–33 wt pct Cu. Metall Mater Trans B. 2012;43:915–924.
- Kenel C, Leinenbach C. Influence of cooling rate on microstructure formation during rapid solidification of binary TiAl alloys. J Alloys Compd. 2015;637:242–247.
- Mattson J, Theisen E, Steen P. Rapid solidification forming of glassy and crystalline ribbons by planar flow casting. Chem Eng Sci. 2018;192:1198–1208.
Language: English
Page range: 13 - 27
Submitted on: Jan 3, 2025
Accepted on: Oct 12, 2025
Published on: Jul 16, 2026
Published by: Bialystok University of Technology
In partnership with: Paradigm Publishing Services
Keywords:
Related subjects:
© 2026 Dinesh Kumar Rajendran, Varthini Rajagopal, Rajaganapathy Chinnachamy, published by Bialystok University of Technology
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 License.