Evolution of modern Casting processes, a competitive way toward very high performance Al components

Purpose of this paper is presenting an overview of alternative methods of production of enhanced performance Al-based alloys components for critical areas. The origin, development and current evolution of the semi-solid metal processing is illustrated with characteristics of real life components for automotive industry. Different techniques are presented to provide a general idea prevalently on the commercially available semi-solid metal processing techniques. Comparison with traditional methods in terms of process parameters and tensile properties are illustrated and discussed. Innovative semi-solid metal processing methods leads obtaining at least the same level of properties and performances of those obtained by conventional techniques, but their real and key benefits are given by a faster production rates at inferior cost. Based on the up to date achieved outcomes, it appears that the current competition is extremely relevant and some concurrent technologies are very competitive. New and recently developed semi-solid metal processing methods show high level of potentiality and at the same time there is a serious need for additional and more detailed rheological data. The continuous increase of Al-based alloys in different applications involves manufacturing high integrity and superior performance components using cost-effective and safely processes. In this direction the research communities together with manufacturing industries are focusing their attention to develop new products using innovative procedures, such as the semi-solid metal processing route. The central issue is the technological transfer to industry for affordable mass production.