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This work describes the processing of different aluminum cast- and wrought alloys in the Cooling-Channel-Process. The investigations take the castability, the microstructural evolution for the SSM-processing and the resulting properties in the test specimen into account. Beside the alloys AlMg5Si2Mn (M59), AlCu4TiMgAg (AF48), AlSi12CuNiMg (SF70), AlSi17Cu4Mg (SF90), AlZnMgCu1,5 (AA7075) the optimization of the alloy AlSi7Mg0,3 (A356) by the addition of magnesium and copper were a main task of the work.

The semi solid forming of steel has the potential of an innovative technology, which could open a new possibility of metal components production. Earlier research works in the 1990s have already shown the principal feasibility of the process but also revealed the various kinds of technical problems. Since then, research works on steel processing have been continuously made in several locations in Japan, USA and Europe. Currently, the focus of these research activities is the development of suitable tool material and the achievement of high part quality, which is the key point for the success of the process. This paper gives an overview of the previous research works and the current state of the research with an outlook on future tasks for this challenge.

In order to broaden the field of application for the innovative thixocasting process, much research is dedicated to the thixocasting of high melting point alloys. The wide property range of modern high alloy steels combined with the productive semi-solid die casting process opens up new fields of application. The Foundry Institute of the Aachen University has therefore been concentrating on the research of the possibilities and limits of high pressure die casting of high alloy steels in the semi-solid state. This paper gives an overview of the current work dedicated to thixocasting of steel alloys by a high pressure die casting machine at the Foundry-Institute of the Aachen University of Technology.In order to understand and describe the material properties in the semi-solid state, basic test specimens have been investigated. Weak points of tool preheating as well as directional solidification of the produced parts can be controlled by numerical simulation of the temperature distribution inside the dies. In consideration of the outstanding flow properties of semi-solid steels more complex geometries with accurately defined applications are now being investigated. Extensive metallographical analyses of the pre-material, the reheated billets and the produced parts have been done to evaluate the viability of the process. The mechanical properties of the specimens outline the outstanding potential of the thixocasting process.

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