Patent ID: 6631753
Filing Date: 2003-10-14
Classification: B22D,B22F,C22B,C23C

Abstract:
A casting system for producing a metal casting from an ingot including defects and any one of oxides, sulfides, contaminants, and other impurities, the metal casting comprising a fine-grain, homogeneous microstructure that is essentially oxide- and sulfide-free, segregation defect free, and essentially free of voids caused by air entrapped during solidification of the metal from a semi-solid state to a solid state, the casting system comprising:an electroslag refining system, the electroslag refining system capable of removing essentially all oxides and sulfides that originate in the ingot; a nucleated casting system, the nucleated casting system having a mold; and a cooling system that supplies coolant directly to the casting through at least one aperture disposed in the mold to cool the metal casting in a manner sufficient to cool a semi-solid portion of the metal casting, wherein the metal casting is cooled in a manner sufficient to provide a microstructure that comprises a fine-grain, homogeneous microstructure that is essentially oxide- and sulfide-free, segregation defect free, and essentially free of voids caused by air entrapped during solidification from a semi-solid state to a solid state.