The production of high-quality light metal die-cast components requires precisely controlled processes in order to optimise material properties and minimise reject rates. A patented technology developed at the AIT Leichtmetallkompetenzzentrum Ranshofen (Light Metal Competence Centre, LKR) now enables a completely new process route for so-called semi-solid casting (SSC) on existing high-pressure die casting systems. 

This development, licensed to Meltec Industrieofenbau GmbH, integrates an innovative inline melt conditioning system that uses electromagnetic stirring to ensure continuous movement of the melt during conditioning. This allows the solidification process to be precisely controlled and the spherical moulding of the material structure to be improved, which has a direct effect on the mechanical properties of the manufactured components. 

Thanks to these technological advances, manufacturers benefit from a significant reduction in porosity and blister formation, optimised mould filling and a reduction in casting pressure, which considerably reduces mould wear. The technology also enables lower processing temperatures and precise control of the solid and liquid phases, which reduces energy consumption and increases tool life by up to 30%. Taken together, this leads to improved component quality and economic optimisation of the entire production process. 

Together with Meltec Industrieofenbau GmbH, the system is being further developed with a focus on industrialisation ready for series production. A prototype that is already in operation provides benchmarks for future developments in the field of semi-solid casting. The great interest shown by other industrial partners illustrates the potential of this technology, which is to be brought to market as part of ongoing funding projects such as Prometheus which is funded by the Austrian Research Promotion Agency (FFG).

 

In the long term, the technology aims to enable more complex component geometries (component substitution, giga-casting), improved weldability and energy-efficient production, which should set new standards in the high-pressure die casting industry.