Machine Casting of Ferrous Alloys

Abstract
Major emphasis was on the development of the Thixocasting process. The Continuous Rheocaster was modified to improve performance and a Softness Indicator was developed to control the Thixocasting reheating stage, thereby eliminating thermocouples. Following production of more than 1000 pounds of the model Copper Alloy 905, more than 800 pounds of AISI 440C and 304 stainless steel was Rheocast in ingot form. Charges, cut from these ingots, were used to produce more than 500 Thixocastings in the copper alloy and over 400 stainless steel Thixocastings. In the course of the work, casting parameter optimization has shown that good Thixocasting practice for these alloys requires equivalent or lower casting pressures than conventional liquid practice and considerably lower metal ingate velocities.

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