Semi-solid metal casting process

Abstract

A method of semi-solid metal casting without the need for retrofitting of conventional casting equipment is provided. A method of direct-feed casting of semi-solid metals is also provided.

1 . A semi-solid metal (SSM) casting process, comprising: 
 providing a metal and a vertical die casting machine,    heating the metal to a chosen temperature,    cooling the metal for a determined period of time to form a semi-solid metal, wherein the time can be zero; and    casting the semi-solid metal in the vertical die casting machine.    
   
   
       2 . An SSM casting process according to  claim 1 , wherein the metal is an Al—Si alloy.  
   
   
       3 . An 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 . An 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 . An SSM casting process according to  claim 2 , wherein Al—Si alloy is a 380 alloy.  
   
   
       6 . An SSM casting process according to  claim 1 , wherein the vertical die casting machine is an indexing type vertical die casting machine.  
   
   
       7 . An SSM casting process according to  claim 5 , wherein the vertical die casting machine is a 1000 Ton Shuttle Machine.  
   
   
       8 . An SSM casting process according to  claim 2 , wherein the vertical die casting machine is an indexing type vertical die casting machine comprising a shot sleeve that indexes between a pour station and a transfer station requiring an indexing time.  
   
   
       9 . An SSM casting process according to  claim 5 , wherein the temperature of metal is chosen such that the metal will form a semi-solid metal as it cools from indexing between the pour station to the transfer station..  
   
   
       10 . An SSM casting process according to  claim 8 , wherein the indexing time is chosen to achieve a determined rate of cooling.  
   
   
       11 . A means for SSM casting, comprising: 
 providing a metal and a vertical die casting means,    heating the metal to a chosen temperature,    cooling the metal for a determined period of time to form a semi-solid metal, wherein the time can be zero; and    casting the semi-solid metal.    
   
   
       12 . A means for SSM casting according to  claim 11 , wherein the metal is an Al—Si alloy.  
   
   
       13 . An A means for SSM casting according to  claim 11 , wherein the vertical die casting means is an indexing type vertical die casting means.  
   
   
       14 . A means for SSM casting according to  claim 13 , wherein the vertical die casting means is a 1000 Ton Shuttle Machine.  
   
   
       15 . A means for SSM casting according to  claim 11 , wherein Al—Si alloy is a hypereutectic Al—Si alloy comprising more than about 11.7 weight percent Si in Al.  
   
   
       16 . A means for SSM casting according to  claim 11 , wherein Al—Si alloy is a hypoeutectic Al—Si alloy comprising less than about 11.7 weight percent Si in Al.  
   
   
       17 . A means for SSM casting according to  claim 11 , wherein Al—Si alloy is a 380 alloy.  
   
   
       18 . A means for SSM casting according to  claim 11 , wherein the vertical die casting machine is an indexing type vertical die casting machine comprising a shot sleeve that indexes between a pour station and a transfer station requiring an indexing time.  
   
   
       19 . A means for SSM casting according to  claim 11 , wherein the temperature of metal is chosen such that the metal will form a semi-solid metal as it cools from indexing between the pour station to the transfer station.  
   
   
       20 . A means for SSM casting according to  claim 11 , wherein the chosen temperature is above the liquidus temperature of the metal.