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SAE TECHNICAL
PAPER SERIES 2003-01-0433

The Use of Semi-Solid Rheocasting (SSR) for

Aluminum Automotive Castings
James A. Yurko
IdraPrince, Inc.

Raul A. Martinez and Merton C. Flemings

Massachusetts Institute of Technology

Reprinted From: Non-Ferrous Castings

(SP-1734)

2003 SAE World Congress

Detroit, Michigan
March 3-6, 2003

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The Use of Semi-Solid Rheocasting (SSR) for Aluminum
Automotive Castings
Copyright © 2003 SAE International
ABSTRACT
Semi-solid metal (SSM) casting has long been identified
as a high-volume process for producing safety-critical and
structural automotive castings, but cost and complexity
issues have limited its widespread commercial
acceptance. Rheocasting, an SSM process that creates
semi-solid slurry directly from liquid metal, eliminates the
cost disadvantages of the process. However, the majority
of rheocasting processes are complex and difficult to
operate in the foundry environment.
Recent work at MIT has led to the fundamental discovery
that application of heat removal and convection as a
molten alloy cools through the liquidus creates a non-
dendritic, semi-solid slurry. A new process based on this
understanding, S.S.R. TM (Semi-Solid Rheocasting),
simplifies the rheocasting process by controlling heat
removal and convection of an alloy during cooling using an
external device. Solution heat treatable castings have
been produced in a horizontal die casting machine with
the S.S.R. TM process. This paper discusses S.S.R. TM in
greater detail and future applications of the process for the
automotive industry.
INTRODUCTION
Semi-solid casting is an alternative forming process that
can produce high integrity castings using a conventional
die casting machine. Unlike conventional processes that
use molten alloy, semi-solid casting uses partially
solidified aluminum or magnesium alloys possessing a
non-dendritic, globular microstructure. Several process
advantages are derived from these two characteristics:
• Decrease of solidification shrinkage because the alloy
has undergone a partial phase transformation outside
of the die cavity
• Decrease in solidification time in the die because of
the reduced latent heat
2003-01-0433
James A. Yurko
IdraPrince, Inc.
Raul A. Martinez and Merton C. Flemings
Massachusetts Institute of Technology
• Planar front filling of the die at relatively high die filling
velocities because of the higher viscosity, non-
Newtonian fluid flow behavior (allows for thin walled,
solution heat treatable castings)
• Decreased thermal fatigue on the die because of
reduced thermal shock (longer die life)
These advantages lead to a process that can create high
integrity, heat treatable castings at cycle times that are
comparable to or faster than die casting. The castings
are near net shape, of complex geometry, and possess
thin and thick walls in the same part.
Previous and existing semi-solid processes have had
limited commercial acceptance because of cost and
processing issues; however, a new semi-solid process
originated at the Massachusetts Institute of Technology
and now under development by IdraPrince, Inc. eliminates
these barriers to commercialization [1-3]. Now known as
the S.S.R. TM (Semi-Solid Rheocasting) Process, this new
technique creates semi-solid slurry quickly and efficiently
from molten alloy.
SEMI-SOLID PROCESSING
Semi-solid processing has two major classifications:
thixocasting and rheocasting. In thixocasting (a.k.a. billet
or slug processes), specially prepared alloy is reheated
from ambient to the semi-solid forming temperature before
casting, while in rheocasting (a.k.a. slurry on demand),
liquid alloy is modified into semi-solid slurry and then
directly formed at the foundry. Figures 1 and 2 are
schematics of the two processes. Through the end of the
last decade, thixocasting was the preferred practice but
only accounted for about 14,000 tons of aluminum
castings worldwide. This amount totals to less than 1% of
all aluminum casting usage [4]. Thixocasting has been
limited in its use because of the high raw material cost
and the inability to recycle scrap from the process.
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Rheocasting, which was identified early in the
development of semi-solid as the most promising SSM
process, eliminates the disadvantages of thixocasting.
Numerous advantages are derived from the nature of the
process:
• Ordinary foundry alloy is used, eliminating the cost
disadvantage of buying special thixotropic billets
• The scrap from a casting can be recycled in-house
and used again with the process
• The alloys used with rheocasting are limitless, unlike
the few alloys currently sold for thixocasting
Figure 1: Thixocasting process: (a) special material cast by the
primary alloy producer, (b) special material shipped to foundry, (c)
material cut to length and reheated to semi-solid forming temperature,
and (d) semi-solid casting.
cools through the liquidus [1,2], with agitation
unnecessary after formation of only a very small fraction of
solid. Instead of relying upon container walls and pouring
to control heat removal and convection, an external stirring
device was used to control these variables. A rotating
copper rod quickly and efficiently produced non-dendritic
microstructure ready for semi-solid forming. Surprisingly,
stirring after the metal temperature dropped below the
liquidus had no impact on final microstructure.
S.S.R. TM was created from the MIT concept, and a
schematic of the process can be seen in Figure 3 [1].
The process is simple and can be divided into three steps.
In step 1, liquid alloy is held slightly above the liquidus
temperature. In step 2, a coated, rotating copper rod is
inserted into the melt which rapidly decreases the
temperature below the liquidus and initiates solidification.
The rod remains in the liquid for a short duration, long
enough to begin solidification throughout the melt. In step
3, the rod is removed and the low solid fraction slurry
cools to the desired forming temperature of semi-solid
casting.

Figure 2: Rheocasting process: (a) molten alloy in the foundry, (b)

process step to convert molten alloy to semi-solid, and (c) semi-solid
casting.

Early rheocasting processes used mechanical stirring to

create the desired non-dendritic microstructure; however,
recent efforts have focused on processes that promote
grain multiplication. Low-temperature (low superheat)
pouring has long been recognized to promote formation of
a fine, equiaxed dendritic microstructure [5], which with
time and slow cooling will coarsen into non-dendritic,
semi-solid material [6]. Simultaneous heat extraction of
the cold vessel receiving the metal and natural convection
of the pour induces this phenomenon. A number of
processes are based on this technique [7-8].
Figure 3: Schematic of the S.S.R. T M process
TM
SEMI-SOLID RHEOCASTING (S.S.R. )

Recent work at M.I.T. led to the realization that the critical

factor for creating non-dendritic, semi-solid slurry is the
combination of rapid cooling and convection as the alloy
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S.S.R. TM experimental studies that vary stirring time and

speed and initial melt temperature show that the process
is very robust. The shape factor of the semi-solid
particles (i.e. the degree of sphericity) is independent of
stirring time, assuming the temperature of the melt drops
below the liquidus. Additionally, the shape factor appears
unaffected by stirring speed in the range of 60 and
approximately 1000 RPM [2]. The capability to remove
varying amounts of heat (stirring time) and control the
amount of convection (stirring speed) in the S.S.R. TM
process allows melt introduction at larger temperature
ranges compared to other rheocasting techniques.
Successful production of semi-solid slurry occurred when
initial melt temperatures varied over 20 ºC (36 ºF) above
the liquidus temperature.

The observation that stirring after the temperature drops

below the liquidus has no effect on microstructure has
profound implications on rheocast process design. Other
rheocasting processes use long stirring times to break up
dendrites and promote coarsening; however, S.S.R. TM
utilizes short stirring to remove super-heat and quickly
initiate solidification throughout the melt
. completed during the spring of 2003. Based on the M.I.T.
Two different castings have been produced with S.S.R. TM,
a fuel pump and a suspension arm, shown in Figure 4.
The shot weight of the suspension arm was 4.85 kg
(10.67 lbs.). Both parts are good examples of castings
that benefit from rheocasting; both components are safety
critical, the fuel pump needs pressure tightness and the
suspension arm requires high strength and ductility after
heat treatment. As seen in Figure 5, X-ray analysis of the
suspension arm casting shows no porosity in a critical
section (a) from Figure 4.
Figure 5: X-ray of safety critical section from a suspension arm
casting, labled (a) in Figure 4.
The first commercial S.S.R. TM apparatus will be
concept, the apparatus will be a modular addition for new
and existing cold chamber die casting machines. The
first unit will produce semi-solid shots of up to 5 kg (11
lbs.). Semi-solid slugs with diameters as large as 150
mm (6 inches) have been produced with S.S.R. TM The
footprint of the apparatus is small, thus allowing it to fit
between a holding furnace and the die casting machine.
THE CASE FOR AN ECONOMICAL SEMI-SOLID
PROCESS

Automotive usage of aluminum castings has grown

tremendously over the last twenty years to a current level
of approximately two million tons in the North American
light vehicle market. Almost 95% of the castings are
produced using either die casting or gravity and low-
pressure permanent mold casting. Forecasts show
continued growth of aluminum automotive castings, with
the majority occurring in areas such as engine blocks and
heads, suspension components, and wheels (see Table 1)
[9,10].

Figure 4: Two castings produced with the S.S.R. T M process, a fuel

pump and a suspension arm. The scale in the foreground is 30.5 cm
(12 in.) in length.
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processes; therefore, they are not discussed in this

study.

Part Name Steering Knuckle

Part Mass 2.9 kg (6.4 lbs.)
Part Dimensions 290 x 250 x 128 mm
(11.5 x 10 x 5 in.)
Surface Area 887 cm2 (137.5 in. 2)
Avg. Wall Thickness 24 mm (0.94 in.)
Max. Wall Thickness 45 mm (1.77 in.)
Estimated Runner and Overflow 70%
Area
Parts per Die 2
Table 1: Current and projected percent usage of aluminum in North Die Life 100,000 shots
American light vehicles by component. Production Volume 500,000 parts/year

Table 2: Process variables used in the cost analysis of a steering

knuckle produced by squeeze, low-pressure and S.S.R. T M casting.
Although die and permanent mold casting processes have
proven to be adequate for a large number of conversions
from cast iron to aluminum over the preceding two
decades, the processes have limitations that make
continued conversions less likely in certain components. The cost per steering knuckle was determined for each of
Producing die castings with the minimal porosity the three processes. Rheocasting solidification time was
necessary for heat treatment is difficult, which limits the assumed to be 40% less than that of squeeze casting,
process’s applicability for structural castings. Low- which corresponded to a 13% decrease in the overall
pressure or gravity permanent mold castings are heat cycle time for rheocasting. processing. Other benefits
treatable and capable of producing high-integrity castings; included in the analysis of rheocasting are increased tool
however, the low die filling velocities of the process require life and decreased part mass due to thin walls. Low-
thick walls in the castings, thus limiting complexity and pressure was approximated to have a 50% longer cycle
geometry. Additionally, the thick walls increase the time and a 50% lower capital equipment cost relative to
solidification time and lead to longer cycle times relative squeeze casting. A summary of the total, variable, and
to a high-pressure die casting process. Rheocasting fixed costs per casting are shown in Table 3.
gives high-pressure die casters the opportunity to
compete with the permanent mold community in capturing Process Cost per Variable Fixed
the rapidly growing wheel and suspension casting Casting Cost Cost
markets because of the ability to produce parts at the low Low-Pressure $13.16 $7.64 $5.53
operating costs and fast cycle times associated with die Squeeze Casting $13.09 $7.28 $5.81
casting. S.S.R. T M Casting with $12.71 $7.20 $5.51
decreased cycle time
S.S.R. T M Casting with $11.59 $7.20 $4.38
A process-based cost model for die casting, developed at
decreased cycle time
the M.I.T. Materials Systems Laboratory, was used to and increased tool life
perform a cost analysis of three different processes: S.S.R. T M Casting with $10.84 $6.46 $4.38
squeeze casting, low-pressure, and rheocasting. The decreased cycle time,
model uses casting and financial data to determine the increased tool life,
cost of a part as a function of any number of variables. thinner wall casting
Melt handling, casting, tooling, and trimming costs are
included, but machining and other secondary operations
are not considered [11]. Table 3: Cost per casting of a steering knuckle casting.

Table 2 provides a summary of the major casting process

variables for production of a steering knuckle. Using
these data, tooling, machine, and cycle time values are
derived. The model includes many other variables, but the
majority of these are constant between the three different
With a short reduction in cycle time relative to squeeze
casting, S.S.R. T M decreases cost by more than 3%. If
the full capabilities of semi-solid are realized, i.e.
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increased tool life and thinner wall castings, the cost [3] Yurko, J.A., Martinez, R.A., and Flemings, M.C.:
savings relative to squeeze casting totals more than 17% Proceedings of the 7th International Conference on
in this example. Overall, the modeling results show that the Processing of Semi-Solid Alloys and
an efficient rheocasting process has significant cost Composites, Tsukuba, Japan, (2002).
savings over the other high-integrity processes.
[4] Chiarmetta, G.: Proceedings of the 6th
International Conference on the Processing of
Semi-Solid Alloys and Composites, Torino, Italy
(200), 15-21.

CONCLUSIONS [5] Flemings, M.C.: Met. Trans. B, vol. 22B (1991),

269-293.
• An improved semi-solid process has been developed
that efficiently produces semi-solid slurry directly from [6] Shibata, R., Kaneuchi, T., Souda, T., Yamane,
ordinary liquid alloy. H., and Umeda, T.: Proceedings of the 5th
• Based on the understanding that the critical International Conference on the Processing of
temperature for creating non-dendritic, globular Semi-Solid Alloys and Composites, Golden, CO
microstructures is at the liquidus temperature, the (1998), 465-470.
S.S.R. TM process uses a minimal duration of stirring
to rapidly remove heat and apply convection to the [7] Xia, K. and Tausig, G.: Mat. Sci. and Eng. A. vol.
melt. A246 (1998), 1-10.
• In less than a year the process has undergone rapid
development, from a laboratory bench scale apparatus [8] Hall, K., Kaufmann, H., and Mundl, A.:
to a soon to be completed modular unit for existing Proceedings of the 6th International Conference on
and new cold chamber die casting machines. the Processing of Semi-Solid Alloys and
• Experiments on the process have shown that it is Composites, Torino, Italy (2000), 23-28.
robust, with large variations of stirring time, stirring
speed, and starting melt temperature having little [9] Schultz, R., Total North American Casting Market
affect on the sphericity of the semi-solid particles. Overview, Ducker Worldwide (2001).
• Automotive castings have been produced with the
process with a mass of approximately 5 kg (11 lbs.) [10] Kirgin, K.H.: Modern Casting, vol 90 (Jan. 2000),
• In addition to providing castings with exceptional 30-33.
mechanical properties, cost models have shown that
S.S.R. TM has economic benefits relative to other high- [11] Urbance, R.J., and Clark, J.P.: unpublished
integrity processes research, Cambridge, MA (2000).

CONTACT

REFERENCES For further information, contact James Yurko, Staff

Metallurgist, IdraPrince, Inc. at (616) 394-8287 or via e-
[1] Martinez, R.A.: S.M. Thesis, Massachusetts mail at jayurko@idraprince.com.
Institute of Technology, Cambridge, MA (2001).

[2] Martinez, R.A., de Figueredo, A.M., Yurko, J.A.,

and Flemings, M.C.: NADCA Transactions,
Cincinnati, OH (2001), 47-54.