In order to improve on the quality of Al-Si alloy billets, which are used as the feed stock for precision forging, a new vertical semi-continuous casting process has been adopted using a heat insulating and rapid cooling mold HI-RCM casting process. In our study, 4032 aluminum alloy billets with smooth surfaces have been obtained by controlling casting rates of HI-RCM process. Distributions of primary silicon, eutectic structure and secondary dendrite arm spacing DAS in the conventional DC casting billets were compared with the smooth surface billets fabricated by HI-RCM casting process under optimum conditions, and the latter one had finer and more homogeneous microstructures than those in the former billets.