Patent ID: 6460595
Filing Date: 2002-10-08
Classification: B22D

Abstract:
A casting system having solid metal particle addition, the casting system forming a casting that comprises a semi-solid portion that receives a stream of a refined liquid metal and a solidified portion, the casting further comprising a fine-grain, homogeneous microstructure that is essentially oxide-free and sulfide-free and is segregation defect free, the casting system comprising:a source of the refined liquid metal, wherein oxides and sulfides have been refined out of the refined liquid metal, and wherein the source provides the stream of the refined liquid metal to the casting; a solid metal particle addition system metal that adds solid metal particles to a surface of the semi-solid portion of the casting such that the solid metal particles are dispersed atop the surface of the semi-solid portion, wherein the solid metal particle addition system is separate from the source of refined liquid metal; and a nucleated casting system for forming the casting, wherein the nucleated casting system is adapted to receive both the solid metal particles and the stream of refined liquid metal to form the casting that comprises a fine-grain, homogeneous microstructure that is essentially oxide-free and sulfide-free and is segregation defect free, wherein the solid metal particle addition system adds the solid metal particles that serve as nucleation centers during solidification of the casting.