Horizontal continuous casting of SSM billets

The economy of semi solid metal casting is highly dependent on the raw material costs, which may account for up to 50% of the total component costs. It is therefore desirable to find cost effective ways to recycle the runners and gates of castings by continuously casting them into fine grained bars suitable as SSM feedstock. The paper describes the development of a horizontal continuous casting technology using circumferential and helicoidal electromagnetic stirring to produce SSM feedstock measuring 3 " in diameter. Based on Hertwich's horizontal casting technology and EFU's experience in vertical continuous casting of SSM billets /1/, experimental work was conducted to adapt the casting parameters (e.g., casting temperature, casting speed, stirring intensity) as well as the mould design. In the course of the project, SSM billets made of A 356 alloy were produced under various process conditions. Optimized billets were then made in larger quantities and subjected to reheating and forming trials. Their behaviour (melt loss, apparent viscosity) was found to be equivalent to other good feedstock material, and die filling during forming of demonstrator components was observed to be normal.