Semi-solid metal casting process

Abstract

A method and product for semi-solid metal casting without the need for retrofitting of conventional casting equipment is provided. A semi solid method is used with a vertical indexing casting machine in which an indexing time can be used as the time to allow the metal that is heated to one temperature to cool to a second temperature before casting. The resulting product from the semi-solid metal casting method with the vertical indexing casting machine is also provided.

1 . A semi-solid metal (SSM) casting process, comprising: 
 providing a metal and a vertical indexing die casting machine,    heating the metal to a first temperature,    cooling the metal to a second temperature to form a semi solid metal based on an index time; and    casting the semi-solid metal in the vertical indexing die casting machine.    
   
   
       2 . The SSM casting process according to  claim 1 , wherein the metal is an Al—Si alloy.  
   
   
       3 . The SSM casting process according to  claim 2 , wherein Al—Si alloy is a hypereutectic Al Si alloy comprising more than about 11.7 weight percent Si in Al.  
   
   
       4 . The SSM casting process according to  claim 2 , wherein Al—Si alloy is a hypoeutectic Al—Si alloy comprising less than about 11.7 weight percent Si in Al.  
   
   
       5 . The SSM casting process according to  claim 2 , wherein Al—Si alloy is a 380 alloy.  
   
   
       6 . (canceled)  
   
   
       7 . The SSM casting process according to  claim 1 , wherein the vertical die indexing casting machine is a 1000 Ton Shuttle Machine.  
   
   
       8 . The SSM casting process according to  claim 1 , wherein the die indexing time is the time that a shot sleeve indexes between a pour station and a transfer station.  
   
   
       9 . The SSM casting process according to  claim 8 , wherein the first temperature is is the temperature that the metal will form a semi-solid metal as it cools from indexing between the pour station in the transfer station.  
   
   
       10 . The SSM casting process according to  claim 1 , wherein the indexing time is chosen to achieve a determined rate of cooling so that the metal reaches a SSM range.  
   
   
       11 . (canceled)  
   
   
       12 . (canceled)  
   
   
       13 . (canceled)  
   
   
       14 . (canceled)  
   
   
       15 . (canceled)  
   
   
       16 . (canceled)  
   
   
       17 . (canceled)  
   
   
       18 . (canceled)  
   
   
       19 . (canceled)  
   
   
       20 . (canceled)  
   
   
       21 . The SSM casting process according to  claim 1 , wherein the first temperature is between about 10° C. to about 15° C. above a liquidus temperature for the metal.  
   
   
       22 . The SSM casting process according to  claim 1 , wherein die first temperature is between about 585° C. to about 595° C.  
   
   
       23 . The SSM casting process according to  claim 22 , wherein the first temperature is between about 590° C. to about 595° C.  
   
   
       24 . The SSM casting process according to  claim 1 , wherein the indexing time is zero.  
   
   
       25 . The SSM casting process according to  claim 1 , wherein the indexing time is between about 0.5 second to about 30 seconds.  
   
   
       26 . The SSM casting process according to  claim 25 , wherein the indexing time is about 0.5 to about 5 seconds.  
   
   
       27 . A cast product made by SSM, comprising: 
 an alloy metal that is heated to a first temperature and transferred to a shot sleeve in a vertical indexing die casting machine, wherein the metal is cooled to a second temperature to form a semi-solid metal based on an index time and is injected into a mold to form the cast product.    
   
   
       28 . The cast product according to  claim 27 , wherein the metal is an Al—Si alloy.  
   
   
       29 . The cast product according to  claim 28 , wherein Al—Si alloy is a hypereutectic Al—Si alloy comprising more than about 11.7 weight percent Si in Al.  
   
   
       30 . The cast product according to  claim 28 , wherein Al Si alloy is a hypoeutectic Al—Si alloy comprising less than about 11.7 weight percent Si in Al.  
   
   
       31 . The cast product according to  claim 28 , wherein Al—Si alloy is a 380 alloy.  
   
   
       32 . The cast product according to  claim 27 , wherein the vertical is indexing casting machine is a 1000 Ton Shuttle Machine.  
   
   
       33 . The cast product according to  claim 27 , wherein the indexing time is the time that the shot sleeve indexes between a pour station and a transfer station.  
   
   
       34 . The cast product according to  claim 27 , wherein the first temperature is the temperature that the metal will form the semi-solid metal as it cools from indexing between a pour station to a transfer station.  
   
   
       35 . The cast product according to  claim 27 , wherein the indexing time is chosen to achieve a determined rate of cooling so that the metal reaches a SSM range.  
   
   
       36 . The cast product according to  claim 27 , wherein the first temperature is between about 10° C. to about 15° C. about a liquidus temperature for the metal.  
   
   
       37 . The cast product according to  claim 27 , wherein the first temperature is between about 585° C. to about 595° C.  
   
   
       38 . The cast product according to  claim 37 , wherein the first temperature is between about 590° C. to about 595° C.  
   
   
       39 . The cast product according to  claim 27 , wherein the indexing time is zero.  
   
   
       40 . The cast product according to  claim 27 , wherein the indexing time is between about 0.5 second to about 30 seconds.  
   
   
       41 . The cast product according to  claim 40 , wherein the indexing time is about 0.5 to about 5 seconds.  
   
   
       42 . The cast product according to  claim 27 , wherein the cast product is an automotive product.  
   
   
       43 . The cast product according to  claim 27 , wherein the product can be selected form a group consisting suspension components, knuckles, control arms, bed plates, swash plates, air conditioning compressor pistons, engine valve bodies and pump housings.