Semi-Solid Forming for Ingot Casting
Ingot casting is the process of producing a solid, three-dimensional shape by pouring a liquid metal into a mold. Semisolid forming (SSF) is a casting process used to produce solid-state shapes from semi-solid metals. The process is based on the rheological properties of a semi-solid metal, which can be manipulated to produce complex shapes with minimal cost, as compared to traditional methods such as die or sand casting.
The first step in the SSF process is to heat the aluminum ingot until it reaches a semi-solid state. This is done by controlling the temperature of the metal, which is generally below its melting point. As the metal is heated, a suspension of evenly-sized discrete particles in a liquid form is created. The second step is to control the shape and size of the particles to achieve the desired shape of the component. To control the size and shape of the particles, a specially designed die is used to create the desired shape. This die can be adjusted to create complex shapes, as well as to control the size of the particles.
Once the desired shape is achieved, the mold is filled with the semi-solid suspension. The suspension is then forced into the mold where it solidifies. This process is done in order to produce components with extremely tight tolerances. The remainder of the process involves cooling, finishing and inspection of the component, in order to ensure it meets all required specifications.
The benefit of SSF for ingot casting is the ability to produce components quickly and with minimal cost, due to its high production rates. Additionally, SSF eliminates the need for additional machining, as the semi-solid material can be shaped directly in the mold, as desired. This process is also highly efficient in terms of material use, as it is capable of producing components with minimal waste.
Overall, SSF is an ideal process for producing components with tight tolerances and complex shapes. It is cost-effective and highly efficient, making it a popular choice for the production of ingot-cast components.
