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A series of iron, nickel, and cobalt base alloys were permanent mold cast under varying conditions to evaluate techniques for improving the integrity of die casting. By appropriate control of heat flow it is possible to achieve permanent mold casting with mechanical properties equivalent to investment castings. Liquid-solid slurries were cast (Rheocasting) to evaluate casting properties and opportunities for enhanced mold life with a reduced temperature casting process. Casting properties are acceptable. It is not clear that there is enhanced mold life by this process.

The program was designed to develop a completely integrated furnace- valve-mold ferrous casting system that will produce quality castings (in the five to twenty-five pound class) at a higher speed and lower cost than is possible by present casting methods. Efforts have been directed in three major areas: Design and fabricate an experimental melting and casting unit capable of examining several casting process possibilities; determine the feasibility of a magnetohydrodynamic (MHD) valve using laboratory scale equipment; and, develop a mold coating for graphite or some other suitable mold material that will provide the properties required of a permanent mold in the automatic casting process envisioned.