Horizontal reheating of aluminum alloys and semi-solid casting for a near net shape compressor component

A semi-solid casting will have a higher internal integrity, mechanical properties and dimensional accuracy than a conventional castings. This process can reduce the manufacturing costs and finished weight for critical components. Semi-solid castings are capable of greater dimensional repeatability, this affording considerable savings when extensive machining, salvage and scrap are key variables in the current automotive product. The most important factors regarding the semi-solid die casting process are the reheating method of the raw materials to the semi-solid state, the specifications of the semi-solid die casting machine, the optimal injection conditions and die design. Thus, in the present work, a horizontal-type induction heating system to obtain the optimal reheating conditions for the semi-solid die casting process was designed and manufactured. The mechanical properties of semi-solid die castings for varying die temperatures, injection velocity and applied pressure were investigated, and the relationship between applied pressure and stroke to assess semi-solid die castability was proposed. Semi-solid die casting experiments to replace heavier cast iron compressor products with lightweight aluminum castings were also carried out. The possibility of their use for compressor parts was verified.