Rapid cycle casting of steel

A rapid cycle casting process for steel via diffusion solidification (SD) is developed. Solidification takes place by carbon redistribution between iron saturated high carbon liquid iron and low carbon preexisting solid iron in a refractory mold. The solidification time is shorter and the economic scaling law is less dependent on the size of the casting than in conventional casting processes. The metallurgical and processing aspects of SD casting are addressed and the necessary parameters are developed to design a rapid cycle casting machine. These process parameters in addition to the metallurgical quality variables are included in an economic feasibility analysis of the SD process.