A system (5) and method (800) for unit cell casting of titanium or titanium-alloys is disclosed herein. The system (5) comprises an external chamber (45), a crucible (10) positioned within the external chamber (45), an induction coil (15) positioned around the crucible, an internal chamber (40) positioned within the external chamber (45), and a mold (30) positioned within the internal chamber (40). The external chamber (45) is evacuated and a pressurized gas is injected into the evacuated external chamber (45) to create a pressurized external chamber (45). An ingot (20) is melted within the crucible utilizing induction heating generated by the induction coil (15). The internal chamber (40) is evacuated to create an evacuated internal chamber (40). The titanium alloy material of the ingot (20) is completely transferred into the mold (30) from the crucible (10) using a pressure differential created between the external chamber (45) and the internal chamber (40).

A suction pressure casting method uses a casting device that includes a holding furnace for accumulating molten metal, a metal mold and a core forming a cavity, a molten-metal pressurizing tank that supplies a pressurizing gas, and a suction and exhaust tank for sucking and exhausting the inside of the cavity. A preset decompression pattern of a casting process is compared with a measured pressure pattern of the cavity and the core that is measured during actual casting. A corrected decompression pattern is calculated based on a difference therebetween. The preset decompression pattern at the time of the next casting is then corrected by using the corrected decompression pattern.

A suction pressure casting method uses a casting device that includes a holding furnace for accumulating molten metal, a metal mold and a core forming a cavity, a molten-metal pressurizing tank that supplies a pressurizing gas, and a suction and exhaust tank for sucking and exhausting the inside of the cavity. A preset decompression pattern of a casting process is compared with a measured pressure pattern of the cavity and the core that is measured during actual casting. A corrected decompression pattern is calculated based on a difference therebetween. The preset decompression pattern at the time of the next casting is then corrected by using the corrected decompression pattern.

A method for manufacturing a steel ingot in a casting arrangement employs a vacuum vessel; an ingot mold arranged within the vacuum vessel, and a stirrer arranged to stir liquid steel in the ingot mold. The method employs the following steps: providing a liquid steel melt; filling the ingot mold with the liquid steel melt; applying a reduced pressure within the vacuum vessel; allowing the liquid steel melt to solidify into an ingot; and allowing the liquid steel melt to solidify under stirring within the ingot mold at a reduced pressure during solidification of the steel melt. The liquid steel melt includes a predetermined amount of carbon and; incidental impurity elements in the form of oxides. During stirring, the oxides are reduced by carbothermic reaction in which oxygen in the oxides and carbon in the steel melt form carbon-monoxide.

A method for manufacturing a steel ingot in a casting arrangement employs a vacuum vessel; an ingot mold arranged within the vacuum vessel, and a stirrer arranged to stir liquid steel in the ingot mold. The method employs the following steps: providing a liquid steel melt; filling the ingot mold with the liquid steel melt; applying a reduced pressure within the vacuum vessel; allowing the liquid steel melt to solidify into an ingot; and allowing the liquid steel melt to solidify under stirring within the ingot mold at a reduced pressure during solidification of the steel melt. The liquid steel melt includes a predetermined amount of carbon and; incidental impurity elements in the form of oxides. During stirring, the oxides are reduced by carbothermic reaction in which oxygen in the oxides and carbon in the steel melt form carbon-monoxide.

An improved aluminum alloy for blending with a recycled aluminum alloy to form a material for high pressure vacuum die casting is provided. The improved aluminum alloy includes 10 to 12 wt. % silicon, 0.65 to 0.85 wt. % manganese, less than 0.05 wt. % iron, less than 0.05 wt. % magnesium, 0.2 to 0.4 wt. % strontium, less than 0.05 wt. % titanium, and less than 0.02 wt. % copper, based on the total weight of the improved aluminum alloy. The recycled aluminum alloy typically includes 0.60-1.0 wt. % silicon, ?0.35 wt. % iron, ?0.20 wt. % copper, 0.05-0.20 wt. % manganese, 0.40-0.8 wt. % magnesium, ?0.20 wt. % chromium, ?0.15 wt. % zinc, ?0.05 wt. % titanium, ?0.05 wt. % others (each), and ?0.15 wt. % others (total). The material meets the specifications for an Aural 5S alloy.

An improved aluminum alloy for blending with a recycled aluminum alloy to form a material for high pressure vacuum die casting is provided. The improved aluminum alloy includes 10 to 12 wt. % silicon, 0.65 to 0.85 wt. % manganese, less than 0.05 wt. % iron, less than 0.05 wt. % magnesium, 0.2 to 0.4 wt. % strontium, less than 0.05 wt. % titanium, and less than 0.02 wt. % copper, based on the total weight of the improved aluminum alloy. The recycled aluminum alloy typically includes 0.60-1.0 wt. % silicon, ?0.35 wt. % iron, ?0.20 wt. % copper, 0.05-0.20 wt. % manganese, 0.40-0.8 wt. % magnesium, ?0.20 wt. % chromium, ?0.15 wt. % zinc, ?0.05 wt. % titanium, ?0.05 wt. % others (each), and ?0.15 wt. % others (total). The material meets the specifications for an Aural 5S alloy.

A casting device includes: a split mold for forming a cavity, including a lower mold, a middle mold that slides in a horizontal direction on the lower mold and an upper mold; a split case for forming a chamber, including a lower case to which the lower mold is attached and an upper case to which the upper mold is attached; a chamber suction device that reduces a pressure at least in the chamber through a chamber pipe that is connected to the chamber and extends to an outside of the chamber; and a cavity suction device that reduces a pressure in the cavity through a cavity pipe that is connected to the cavity and extends to the outside of the chamber. The cavity and the chamber are formed when the middle mold is closed on the lower mold and the split case is closed.

A casting device includes: a split mold for forming a cavity, including a lower mold, a middle mold that slides in a horizontal direction on the lower mold and an upper mold; a split case for forming a chamber, including a lower case to which the lower mold is attached and an upper case to which the upper mold is attached; a chamber suction device that reduces a pressure at least in the chamber through a chamber pipe that is connected to the chamber and extends to an outside of the chamber; and a cavity suction device that reduces a pressure in the cavity through a cavity pipe that is connected to the cavity and extends to the outside of the chamber. The cavity and the chamber are formed when the middle mold is closed on the lower mold and the split case is closed.

Disclosed are an aluminum alloy composition for die casting and a method of heat treating the same. The aluminum alloy composition contains precipitation of an MgZn-based strengthening phase through heat treatment to thus enhance strength thereof.