Worcester Polytechnic Institute Electronic Theses and Dissertations Collection

Title page for ETD etd-082305-102150

Document Typethesis
Author NameBernard, III, William J.
TitleThe Continuous Rheoconversion Process: Scale-up and Optimization
DepartmentMaterials Science & Engineering
  • Diran Apelian, Advisor
  • Richard D. Sisson, Jr., Department Head
  • Keywords
  • CRP
  • thixocasting
  • rheocasting
  • semisolid
  • Date of Presentation/Defense2005-08-04
    Availability unrestricted


    Semi-solid metal (SSM) processing has emerged as a preferred manufacturing method due to the superior quality associated with semi-solid castings. In recent years, the driving force to reduce process cost has led to the development of a few rheocasting (also termed slurry-on-demand) processes. These include UBE’s New Rheocasting (NRC) process [1], Idra Prince’s Semi-Solid Rheocasting (SSR) process [2], and THT’s Sub-Liquidus Casting (SLC®) process [3]. A novel slurry-making SSM process developed at ACRC/MPI, termed the “Continuous Rheoconversion Process” (CRP), is a passive liquid mixing technique in which the nucleation and growth of the primary phase are controlled using a specially designed “reactor”. The reactor provides heat extraction, copious nucleation and forced convection during the initial stage of solidification, leading to the formation of thixotropic structures. In these studies, the critical issues/challenges to optimize the CRP for industrial applications have been addressed through validation experiments and pre-industrial trials.

  • wbernard.pdf

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