This paper presents an analysis of an advanced squeeze casting process suitable for the manufacturing of high performance industrial components more quickly and cheaply. After short description of the process some produced components are considered. The components, in A356 and A380 alloys, have been T6 heat treated and their soundness has been certified by non destructive tests. Standard samples for impact test, as well as for fracture rupture strength have been machined directly from the previous components. After the execution of the tests the fracture surface of samples has been observed by SEM in order to analyze details and to evaluate the influence of the process and of the alloy on the fracture behaviour. On polished transverse sections of samples the microstructure of the alloy has been observed, highlighting the presence of very small and uniformly distributed intermetallic particles in a mainly globular shaped microstructure as expression of the attained semi-solid conditions during the process.

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In this paper a self-hardening Al-based alloy (AlZn10Si8Mg) is proposed for automotive applications as an alternative to the A357 (AlSi7Mg0.6) T6 heat treated alloy. The properties of the AlZn10Si8Mg alloy have been monitored and compared to those of the A357 alloy which is already employed in the targeted automotive industry. The samples have been submitted to microstructural analysis and mechanical characterization, while the presence of defects on the fractured surface has been identified by fracture surface analysis. A relationship between defects and mechanical performances has been identified. The corrosion resistance of the alloys has also been investigated according to the Standard BS 11846. On the basis of the results obtained till now, the AlZn10Si8Mg alloy is a good candidate for the proposed automotive application.

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