Abstract: A numerical procedure for simulating the behavior of incompressible, viscous fluid in a casting/molding process. The method is based on classical fluid dynamic equations and uses control volume-finite element and numerical techniques to solve the momentum and energy equations to obtain solution for the variable parameters. The method incorporates five additional modules which simulate fluid flow in the shot sleeve, heat transfer between the die and the heat transfer fluid, die cooling by lubricant, formation of mend line. These additional simulation modules produce realistic boundary conditions, and replace many of the assumptions that would have to be made, to solve the governing equations. These added improvements ensure a faster convergence of the numerical solution and a more realistic simulation of the die casting process.

Abstract: A container system including a vessel for holding a thixotropic semi-solid aluminum alloy slurry during its processing as a billet and an ejection system for cleanly discharging the processed thixotropic semi-solid aluminum billet. The crucible is preferably formed from a chemically and thermally stable material (such as graphite or a ceramic). The crucible defines a mixing volume. The crucible ejection mechanism may include a movable bottom portion mounted on a piston or may include a solenoid coil for inducing an electromotive force in the electrically conducting billet for urging it from the crucible. During processing, a molten aluminum alloy precursor is transferred into the crucible and vigorously stirred and controlledly cooled to form a thixotropic semi-solid billet. Once the billet is formed, the ejection mechanism is activated to discharge the billet from the crucible. The billet is discharged onto a shot sleeve and immediately placed in a mold and molded into a desired form.