The continuous rheoconversion process (CRP™): optimization & industrial applications

Abstract

Semi-solid metal (SSM) processing has emerged as a preferred manufacturing scheme due to the superior quality associated with semi-solid castings. In recent years, the driving force to reduce process cost requires the development of robust, commercially viable rheocasting (also termed slurry-on-demand (SoD)) processes. The continuous rheoconversion process (CRP™) is a novel SoD process that was developed at MPI/ WPI. The process is based on a passive liquid mixing technique in which the nucleation and growth of the primary phase are controlled using a specially designed "reactor". The reactor provides heat extraction, copious nucleation, and forced convection during the initial stage of solidification, thus leading to the formation of globular structures. This paper presents our recent work on the optimization of the CRPTM for industrial applications. Specifically, we will discuss critical issues of optimizing and simplifying the process to retrofit most die casting facilities. Salient results from simulations and several industrial trials that have been carried out with ACRC Consortium Members are reviewed and discussed.