The official published version of the article can be accessed at the link below.It has been demonstrated recently that intensive melt shearing can be an effective approach to the grain refinement of both shape casting and continuous casting of Mg alloys. In the present study, the mechanisms of grain refinement by intensive melt shearing were investigated through a combination of both modelling and experimental approaches. The measurement of the cooling curves during solidification, quantification of grain size of the solidified samples, and image analysis of the MgO particle size and size distribution in the pressurized filtration samples were performed for the AZ91 alloy with and without intensive melt shearing. The experimental results were then used as input parameters for the free growth model to investigate the mechanisms of grain refinement by intensive melt shearing. The experimental results showed that, although intensive melt shearing does not change the nucleation starting temperature, it increases the nucleation finishing temperature, giving rise to a reduced nucleation undercooling. The theoretical modelling using the free growth model revealed quantitatively that intensive melt shearing can effectively disperse MgO particles densely populated in the oxide films into more individual particles in the alloy melt, resulting in an increase in the MgO particle density by three orders of magnitude and the density of active nucleating MgO particles by a factor of 20 compared with those of the non-sheared melt. Therefore, the grain refining effect of intensive melt shearing can be confidently attributed to the significantly increased refining efficiency of the naturally occurring MgO particles in the alloy melt as potent nucleation sites.Financial support under Grant EP/H026177/1 from the EPSRC

It is well accepted in the literature that for effective grain refinement some solute is required in the melt to restrict the growth of the solid even if potent nucleating particles with a favourable physical nature are present. In this paper, we investigate the effect of solute on grain initiation in an isothermal melt, and an analytical model is developed to account for the effect of solute elements on the grain size. This study revealed that the solute elements in the liquid ahead of the growing crystals reduce the growth velocity of the nucleated crystals, and increase the maximum undercooling achievable before recalescence. This allows for more particles to be active for nucleation, and consequently increases the number density of active particles, giving rise to a finer grain size. The analytical model shows that the final grain size can be related to the maximum undercooling, average growth velocity and solid fraction at the moment of the recalescence. Further analysis using the free growth model and experimental data in the literature revealed that for a given alloy system solidified under similar conditions the grain size can be empirically related to 1/Q (Q is the growth restriction factor) to a power of 1/3, which is considerably different from the empirical linear relationship in the literature. It is demonstrated that the 1/3 power law can describe the experimental data more accurately than a linear relationship.

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