However, the predominant structure under common casting conditions is dendrite morphology which adversely affects materials performance. Although initial microstructure might be altered by later thermal and mechanical treatments, the dendritic pattern cannot be fully removed. Alternatively, performance improvement can be approached by alteration/control of growth morphology as well as refining. Concept of Semi-Solid Metal (SSM) processing (processing within mushy zone) has been introduced as a family of routes toward non-dendritic microstructure.

In this context, Inclined Cooling Plate (ICP) method is a recent solution where due to flowing of alloy melt down an inclined cold plate, a semi-solid mixture is produced with a fine, uniform and non-dendritic solid phase suitable for thixo-casting/forming processes.

In this paper, an ICP analog system is described that – by transparent model alloy – visualizes the behavior of the metal alloy. Experiments show that forced-convection across solid/liquid interface modifies the structure of mushy zone of the alloy compared with conventional casting processes. In detail, the cooling effect of plate generates numerous solid grains which are subjected to crossing melt flow. As a result, these grains are fragmented into myriad of fine particles and washed to downstream. Then, in thermally and compositionally uniform ambient main flow, these fragments can grow with cellular morphology in radial directions. Indeed, the combined effects of solidification and fluid flow are utilized in ICP to develop such microstructure with fine-and-uniformly-distributed-radially-grown-cells within liquid pool.  The present study also clarifies how the ICP-processed alloys might be considered as alternative aerostructural material for either continuous ingot in subsequent forming or discrete part through near net shape manufacturing.