Spx Corporation

Worcester Polytechnic Institute

Deepak Saha

Diran Apelian

Mark Musser

Zach Brown

Dayne Killingsworth

Sumanth Shankar

Makhlouf M Makhlouf

Preferred embodiments of the present invention include methods that allow for casting alloys, and preferentially casting wrought alloys to circumvent problems such as, for example, hot tearing. Preferred embodiments of the present invention provide for alloys having predominantly spherical primary &#x3b1;-aluminum grains in their microstructure (i.e., substantially free of dendrites) formed by mixing two liquids of differing compositions that are held at predetermined temperatures, such that when mixed they produce a predetermined alloy composition at a predetermined temperature that is inclined to solidify with a predominantly spherical grain structure that minimizes the alloy's tendency towards hot tearing.

Casting of aluminum based wrought alloys and aluminum based casting alloys

A method for the refining of primary aluminum in hypoeutectic alloys by mixing a titanium based grain refiner into a solid/semi-solid hypoeutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Al in a hypoeutectic Al&#x2014;Si casting by mixing a hypoeutectic Al&#x2014;Si liquid with titanium boron alloys. The invention enables grain refining techniques for SSM casting of hypoeutectic Al&#x2014;Si alloys.

Semi-solid casting process of aluminum alloys with a grain refiner

A method for the refining of primary silicon in hypereutectic alloys by mixing at least two hypereutectic alloys into a solid/semi-solid hypereutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Si in a hypereutectic Al&#x2014;Si casting by mixing a hypereutectic Al&#x2014;Si liquid with solid hypereutectic Al&#x2014;Si particles. The invention enables SSM processing of hypereutectic Al&#x2014;Si alloys.

Semi-solid metal casting process of hypereutectic aluminum alloys

A method for the refining of primary aluminum in hypoeutectic alloys by mixing at least two hypoeutectic alloys into a solid/semi-solid hypoeutectic slurry is described. The method provides control of the morphology, size, and distribution of primary Al in a hypoeutectic Al&#x2014;Si casting by mixing a hypoeutectic Al&#x2014;Si liquid with solid hypoeutectic Al&#x2014;Si particles to impart desirable mechanical properties. The invention enables SSM molding of hypoeutiectic alloys without the need for secondary processing steps associated with other rheocasting processes.

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Worcester, MA, United States of America

Deepak Saha