Classified into high solid fraction and low solid fraction semi-solids.
The critical steps are slurry preparation and production process control.
Compared to squeeze casting, semi-solid die casting includes an additional slurry preparation step. During slurry preparation, the molten metal temperature is significantly lower than in squeeze casting or conventional die casting—this reduces dissolved hydrogen absorption, resulting in a cleaner melt with less porosity potential.
The solid-liquid coexisting state of semi-solid metal gives it higher viscosity than fully liquid metal, which promotes laminar flow (minimizing chaotic turbulence). When combined with a low-speed high-pressure (LSHP) injection system, this viscosity ensures more uniform, defect-free filling—even for complex geometries—reducing cold shuts or misruns.
In semi-solid casting, the solid fraction suppresses gas release during solidification (vs. pure liquid metal, which releases more gas as it cools). Lower gas entrapment means fewer internal pores, making semi-solid parts far more suitable for T6 heat treatment (a common post-cast step to enhance strength—porosity would otherwise cause blistering or distortion).
Semi-solid metal’s lower heat content and slower solidification rate reduce thermal shock to the mold (a major cause of cracking or wear in high-production die casting). This extends mold lifespan and lowers long-term maintenance costs.
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