Abstract: A metal composition characterized by greater than about 65 weight percent degenerate denritic or nodular primary discrete solid particles suspended in a secondary phase having a lower melting point than the primary particles and which secondary phase can be solid or liquid. The method involves raising the temperature of a metal alloy to a value at which the alloy is largely or completely in the molten state. The melt is then subjected to vigorous agitation in an apparatus having an inner surface contacting the liquid-primary solid composition that is not wet by the composition and the heat is extracted to increase the portion of the mixture is in solid degenerate dendrite or nodular form greater than about sixty-five percent while continuing the agitation.

Abstract: Liquid-solid ferrous compositions containing up to about 85 weight percent degenerate dendrites by vigorously agitating a partially solidified ferrous composition in an agitation zone to form degenerate dendrites while preventing the formation of interconnected dendritic networks. The interior surface of the agitation zone and the agitator is formed of high density recrystallized aluminum which remains stable against degradation by the partially molten ferrous composition and is not wet by the ferrous composition. An inert or protective gas blanket is maintained at the outlet of the agitation zone to prevent oxidation and slag formation thereby to prevent clogging of the outlet.

Abstract: A process is provided by determining the castability of a metallic composition comprising a metal matrix containing secondary solid and discrete degenerate dendrites. The composition is heated and a calibrated probe is contacted under force to the surface of the composition and a parameter of distance the probe travels into the composition as a function of the force is determined. The composition is castable when the parameter measured corresponds to the condition when at least about 50 wt. % of the secondary solid is liquified and between about 25 and 90 wt. % of the total composition is liquified.