Cold Chamber Die Casting
For aluminum and magnesium components requiring structural strength, dimensional stability and CNC post-machining support.
Explore Cold Chamber →SEMI-SOLID METAL CASTING
Semi-Solid Metal Casting for High-Performance OEM Components
FSD Precision supports semi-solid metal casting solutions for lightweight, high-strength components requiring improved mechanical performance, reduced porosity and near-net-shape production.
ISO 9001 Quality SystemConfidential Project HandlingEngineering Support Available
DIRECT ANSWER
What Is Semi-Solid Metal Casting?
Semi-solid metal casting, also known as SSM or semi-solid die casting, is an advanced manufacturing process where metal is formed in a controlled thixotropic state with a typical solid fraction of about 30%–50%.
Compared with conventional die casting, semi-solid metal processing improves flow control, reduces turbulence and supports low porosity aluminum and magnesium components with better mechanical performance.
For suitable alloys such as A356 and A357, semi-solid aluminum casting can support T4, T5 and T6 heat treatment. This helps solve a common high pressure die casting limitation where internal porosity can restrict heat treatment, welding and high-performance structural applications.
Process StateSemi-Solid State
Flow BehaviorReduced Turbulence
Porosity TargetLow Porosity
Heat TreatmentT6 Heat Treatment Capable
Performance TargetImproved Mechanical Performance
MATERIAL STATE TRANSFORMATION
How Semi-Solid Metal Casting Works
The semi-solid casting route transforms metal from solid preparation into a controlled semi-solid state before forming the final component.
01
Solid Metal Preparation
02
Semi-Solid Slurry Formation
03
Controlled Injection
04
Solidification
05
Part Removal
06
Machining & Finishing
Semi-solid casting controls metal behavior between liquid and solid states to improve flow stability, reduce turbulence and support high-performance component production.
PROCESS COMPARISON
Semi-Solid Casting vs Conventional Die Casting
| Factor | Semi-Solid Casting | Conventional Die Casting |
|---|---|---|
| Metal State | Semi-solid slurry | Fully liquid metal |
| Flow Control | Better control | Higher turbulence |
| Process Control | Controlled metal flow | Higher turbulence risk |
| Porosity | Reduced risk | Higher risk |
| Mechanical Properties | Improved | Standard |
| Applications | High-performance parts | General production parts |
Compare Other Casting Processes: Cold Chamber Die Casting and Hot Chamber Die Casting.
ADVANCED CASTING ADVANTAGE
Why Choose Semi-Solid Metal Casting?
Semi-solid metal casting is selected when OEM components need lower porosity risk, improved strength and controlled metal flow for advanced casting technology projects.
Lower Porosity
Controlled Metal Flow
Semi-solid slurry behavior helps reduce turbulence and supports more stable filling for high-performance metal components.
Mechanical Performance
Improved Material Structure
Rheocasting and thixocasting routes can improve consistency where strength and reliability are important.
Near-Net Shape
Complex Lightweight Components
Semi-solid aluminum casting supports lightweight geometry with reduced finishing and machining risk.
TECHNOLOGY METHODS
Semi-Solid Metal Casting Methods
Rheocasting
Prepared Metal Slurry
Metal slurry is prepared before injection, improving flow control and reducing defects.
Liquid Metal→Slurry Preparation→Casting
Thixocasting
Reheated Semi-Solid Billet
Pre-solidified billets are reheated into a semi-solid state before forming.
Pre-Solidified Billet→Reheating→Forming
MATERIAL SELECTION
Semi-Solid Metal Casting Materials
| Material | Details |
|---|---|
| A356 Aluminum | Lightweight structural components with mechanical performance and casting stability. |
| A357 Aluminum | High-performance aluminum parts requiring improved strength and fatigue performance. |
| 6061 Aluminum | Special aluminum applications where lightweight design and machinability are required. |
| AZ91 Magnesium | Weight reduction applications requiring a high strength-to-weight ratio. |
For aluminum casting requirements, explore our Aluminum Die Casting Solutions. Lightweight projects can also be reviewed through Magnesium Die Casting Support.
Engineering Capability & Tolerance Parameters
| Details | |
|---|---|
| Min Wall Thickness | 1.5 mm – 2.0 mm. Feature dependent; uniform wall design improves filling stability. |
| Dimensional Tolerance | ISO 8062 CT4 – CT6. Critical datums can be finished by CNC machining. |
| Porosity Standard | ASTM E505 Level 1 - Level 2. Low porosity target depends on process validation and inspection plan. |
| Heat Treatment | T4, T5 and T6 capable for suitable semi-solid aluminum alloys after casting. |
| Surface Roughness | Ra 1.6 – 3.2 µm as-cast. Final surface depends on tooling, process route and finishing requirements. |
APPLICATIONS
Semi-Solid Casting Applications
Why Semi-Solid?
Automotive Lightweight Components
Weight reduction and improved strength for high-performance vehicle structures.
Why Semi-Solid?
High Strength Aluminum Components
Near-net-shape production for engineered metal components.
Why Semi-Solid?
Aerospace Lightweight Components
Reduced porosity risk for demanding mechanical applications.
DESIGN REVIEW
Semi-Solid Metal Casting Design Guidelines
| Design Factor | Risk | Engineering Solution |
|---|---|---|
| Wall Thickness | Uneven Filling | Uniform Wall Design |
| Geometry | Flow Problems | Optimize Transitions |
| Ribs | Defects | Balanced Reinforcement |
| Machining Allowance | Tolerance Variation | Plan Secondary Machining |
CAPABILITY
Semi-Solid Casting Capability
Aluminum / Magnesium
Material routes for semi-solid aluminum casting and lightweight magnesium projects.
Semi-Solid Forming
Controlled metal state for improved flow behavior and reduced turbulence risk.
High Performance Components
Suitable for lightweight parts requiring strength, stability and near-net-shape production.
Prototype → Production
Engineering review supports process validation before repeat manufacturing.
CNC Machining
Post-machining support for critical datums, holes, threads and precision interfaces.
Critical features can be completed through CNC Machining and Surface Finishing operations.
QUALITY CONTROL
Semi-Solid Casting Quality Control
01
Material Structure Analysis
02
Microstructure Evaluation
03
Porosity Evaluation
04
Dimensional Inspection
05
Final Inspection
FAQ
Semi-Solid Metal Casting FAQ
What is semi-solid metal casting?
Semi-solid metal casting forms metal while it is partially solid and partially liquid, improving control during forming.
How is semi-solid casting different from die casting?
Conventional die casting injects fully liquid metal, while semi-solid casting uses a controlled slurry to reduce turbulence and porosity risk.
What materials can be used in semi-solid casting?
Common materials include selected aluminum alloys such as A356, A357 and 6061, plus magnesium alloys for weight reduction projects.
What are the benefits of semi-solid casting?
Benefits include reduced porosity risk, improved mechanical performance, better flow control and near-net-shape production.
Is semi-solid casting suitable for aluminum parts?
Yes. Semi-solid aluminum casting can support high-performance components requiring strength, lightweight design and defect control.
What is the difference between Rheocasting and Thixocasting?
Rheocasting prepares a semi-solid slurry before injection, while thixocasting reheats a pre-solidified billet into a semi-solid state before forming.
Can semi-solid cast parts be CNC machined?
Yes. CNC machining can be added for tight tolerances, threaded features, sealing surfaces and precision interfaces.
What information is needed for quotation?
Send 3D files, 2D drawings, material requirements, annual volume, surface requirements and performance targets.
PROCESS SELECTION
Not Sure Which Casting Process Fits Your Project?
Compare cold chamber, hot chamber and semi-solid casting routes before tooling review.
Cold ChamberHot ChamberSemi-Solid Casting
ENGINEERING RFQ
Discuss Your Semi-Solid Casting Project
Send your drawings and project requirements. Our engineering team will review process suitability, material selection and manufacturing requirements.