This document summarizes a presentation about an improved lost foam casting method called Eco ChillTM, which provides adjustable directional and rapid cooling. Eco ChillTM can cast complex shapes, reduce porosity and hot tearing, and optimize mechanical properties. It allows casting of alloys not previously castable and improves properties of mainstream alloys. The method is more effective than shape casting and could cast wrought alloys through gravity casting.

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
Excerpts of the presentation presented at AFS 116th
Metalcasting Congress
April 17-20,2012 - Columbus, OH USA
IMPROVED APPARATUS
AND METHOD FOR
CONTROLLED OPTIMIZED
RAPID DIRECTIONAL
SOLIDIFICATION OF MOLD
SHAPED METAL CASTINGS
By Charles Rau
Eco Squared Solutions, Inc.

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
One classic fundamental mechanism
of casting failure is porosity
• Rapid solidification reduces porosity and
improves mechanical properties
• Controlled and directional solidification helps
minimize porosity, optimize mechanical
properties and cast otherwise non-castable
alloys and non-uniform shapes

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
Shape casting is less expensive than
forging
• Shape casting wrought alloys with the low
eutectic content encounter stresses in the
mold cavity during solidification
• Hot tearing at the grain boundaries near the
edge of solidification is a typical phenomenon

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
While shape casting is less expensive than
forging, lost foam casting is a better process.
This is why an improved lost foam casting
method will fair even better. Since there is little
resistance of the mold to restrain the solidification
like a steel die that creates tensile force on the
solidifying casting. A strong temperature cooling
gradient quickens solidification process - liquid
to solid.
Lost foam versus shape casting

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
ESSI has created a new patented process for lost
foam casting. We call this Eco Chill™- Adjustable
Directional and Rapid Cooling Process which is novel
and unique and heretofore historically, has never
been achieved.
• Improves the castability of mainstream cast alloys and
many wrought alloys with modifications to the base
alloy chemistry and grain refinement
• As a result, our Eco Chill™ system will significantly
reduce the hot tearing factor
“Eco Chill™”
– Adjustable Directional
and Rapid Cooling Process

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
Casting alloy designations
aluminum association numbering system
Series Chemistry End Uses
1XX.X 99% Minimum Aluminum Low strength, high conductivity, e.g. rotor cages
for electric motors, busbars, etc.
2XX.X Al + Cu Very high strength cast parts
3XX.X Al + (Si + Mg, Si + Cu, Si + Mg
+Cu)
Engine components, wheels, aerospace structural
castings, almost anything
4XX.X Al + Si Intricate castings and non-heat treated parts,
wheels (European)
5XX.X Al + Mg Castings required excellent surface finish and/or
corrosion resistance. Marine applications, food
preparation
7XX.X Al + Zn +Mg Naturally ageing alloys with excellent surface
finish and high dimensional stability e.g. molds
for blow-molding plastic bottles. Brazable
8XX.X Al + Sn + Cu (+Si) Bearings and bushings

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
Shrinkage 
Porosity 
Hot tears 
What about gravity casting of wrought
alloys?

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
The four main feeding mechanisms
Liquid Feeding
Mass Feeding
Intergranular
and Interdendritic
Feeding
Solid Feeding

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
(Source: A. Kearney, “Hot Tear Control Handbook for Aluminum Foundrymen and Casting Designers”, American Foundrymen’s
Society, Des Plaines, Illinois)
Schematic drawings of the origins of hot tearing and the
need to feed solidification shrinkage

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
43μm Cell Size
73μm Cell Size
End-chilled mould
Simulation of casting processes / solidification rates
Freezing rate and cell size

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
Eco Chill’sTM
range

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
Automotive suspension part. The thickness of, and hence freezing rate experienced by
different regions within a casting lead to highly non-uniform properties. This must be
considered during the design phase. Eco Chill™ can custom control the solidification
rate of the thick and the thin areas for more uniform properties.
6-8%
8-10%12-15%
Example: part geometry & freezing rate

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
Elongation with dendrite arm spacing (µm)
Secondary Dendrite Arm Spacing (µm)
%ElongationExample: part geometry & freezing rate

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
• ESSI has not seen much grain growth in a fast
solidification casting
• As it has been proven, the DAS (solidification
rate which control the size of embrittling inter-
metallics) is the prime determinant of
mechanical properties particularly ductility and
UTS. Yield is a function of composition and
heat treatment
Benefits of fast solidification rate

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
Direct chill casting
Very old technique in the Al industry
 Semi-Continuous Casting
 Ensures short freezing range
 Ensures strong directional freezing
Used for:
 As small as
2” diameter
billets on the
small side
 Up to 20
tonne
36”x72”
sheet ingots

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
Direct chill casting in pre-shapes
Used for:
 Casting pre-shaped ingots
 Sliced and forged into net
shape

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
We wish to thank for help, advice, support, and assistance:
• American Foundry Society
• Rio Tinto Alcan (formally Alcan International)
• Eck Industries Inc.
• Custom Alloy Light Metals
• Carbo Ceramics
• Asbury Graphite Mills LLC
• Flow Science Inc.
• Metal Test Inc.
• NorthWest Laboratories Inc.
• HA International LLC

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reproduced or used without the prior permission of Eco Squared Solutions, Inc.
For additional information, please contact:
Eco Squared Solutions, Inc.
6220 CROMWELL DRIVE N.W.
GIG HARBOR, WASHINGTON, 98335, USA
www.ecosqrd.com
800-201-5439
 Charles Rau – Founder & CTO
Mobile: 253-241-9497
FAX: 253-265-3432
Email: crau@ecosquaredsolutions.com
 Rod Herring - CMO
Mobile: 310-926-1066
Email: rod@ecosqrd.com