Favorable alloy compositions and melt temperatures to cast 2XXX and 7XXX Al alloys by controlled diffusion solidification (CDS)

Controlled diffusion solidification (CDS) is an innovative rheocasting (Semi-solid) processing route to obtain a cast part with a non-dendritic morphology of the primary Al phase. The process involves mixing two alloy melts with specific individual compositions and temperatures to produce the desired final alloy by mixing and immediately casting in a mold. The process enables the shape casting of Al based wrought alloy along with their superior cast properties and performance. The present work defines process conditions to enable shaped casting of the 2XXX and 7XXX series of Al based wrought alloys, specifically, 2024, 7005 and 7075 alloys.