New Rheocasting (NRC) is a novel semi-solid casting process in which fully liquid melts are transformed into slurries right at the pressure casting machine, which then forms the slurries into high quality shape castings. The basic concept of NRC is explained and possible production equipment is introduced. The process is based on controlled cooling of a slightly superheated melt. This controlled cooling is performed in a carousel slurry maker. Fundamental investigations on the semi-solid castability of AZ and AM alloys were made in a trial step die, and are now compared with results achieved in NRC-cast suspension parts. For this purpose a suspension arm with 1.6 kg shot weight is cast on an UBE HVSC 350 Vertical Squeeze Casting machine. Technical and economical aspects of the use of NRC -Magnesium in structural parts will be discussed, taking into account the use of lower cost recycling material.
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