Thixoforming : Semi-solid Metal Processing

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6.1.2.1 Approach from Fluid Mechanics 172 6.1.3 Approach from Solid-state Mechanics 174 6.1.4 Experimental Investigations to Determine Model Parameters 175 6.1.5 Experimental Setups 175 6.1.5.1 Rotational Rheometer 175 6.1.5.2 Capillary Rheometer 177 6.1.5.3 Vertical Capillary Rheometer 178 6.1.5.4 Horizontal Capillary Rheometer 179 6.1.5.5 Compression Test 182 6.1.6 Experimental Results and Modelling 183 6.1.6.1 Rotational Rheometer 183 6.1.6.2 Capillary Rheometer 189 6.1.6.3 Compression Tests 193 6.2 Numerical Modelling of Flow Behaviour 196 6.2.1 Motivation 196 6.2.2 Numerical Models Used 197 6.2.2.1 Material Models 197 6.2.2.2 Discretization Methods (Numerical Solution Techniques) 199 6.2.3 Software Packages Used 200 6.2.4 Numerical Examples 201 6.2.4.1 One-phase, Finite Difference, Based on Flow-3d 201 6.2.4.2 Two-phase, Finite Element Based on PETERA 202 6.2.5 Summary 208 6.3 Simulation of Cooling Channel 208 6.3.1 Model Description 209 6.3.2 Determination of Grain Nucleation Parameters 209 6.3.3 Process Simulation 210 6.3.4 Summary 215 References 217 Contents IX 7 A Physical and Micromechanical Model for Semi-solid Behaviour 221 Véronique Favier, Régis Bigot, and Pierre Cézard 7.1 Introduction 221 7.2 Basic Concepts of Micromechanics and Homogenization 222 7.3 Modelling Semi-solid Behaviour 223 7.3.1 Definition of the Representative Volume Element 223 7.3.1.1 Morphological Pattern 223 7.3.1.2 Internal Variable 225 7.3.1.3 Local Behaviours 226 7.3.2 Homogenized Estimate of the Semi-solid Viscosity: Concentration and Homogenization Steps 227 7.3.2.1 Step a 227 7.3.2.2 Step b 229 7.4 Results and Discussion 229 7.4.1 Isothermal Steady-state Behaviour 229
X Contents 7.4.2 Isothermal Non-steady-state Behaviour 232 7.4.3 Non-isothermal and Non-steady-state Behaviour 234 7.5 Conclusion 235 References 237 Part Three Tool Technologies for Forming of Semi-solid Metals 239 8 Tool Technologies for Forming of Semi-solid Metals 241 Kirsten Bobzin, Erich Lugscheider, Jochen M. Schneider, Rainer Telle, Philipp Immich, David Hajas, and Simon Münstermann 8.1 Introduction – Suitable Tool Concepts for the Thixoforming Process 241 8.2 Thin-Film PVD/PECVD Coating Concepts for Die Materials 247 8.3 PVD and PECVD Coating Technologies 249 8.4 Multifunctional PVD Composites for Thixoforming Moulds 251 8.4.1 Deposition Process Development of Crystalline PVD Al 2O3 254 8.4.1.1 Experimental Details for the Development of g-Al2O3 255 8.4.1.2 Results and Discussion 255 8.4.1.3 Summary of the Development of the TiAlN–g-Al2O3 Bilayer System 256 8.4.1.4 Upscaling g-Al2O3 from a Laboratory-scale Unit to an Industrial Coating Unit 257 8.4.1.5 Experimental Details for the Development of g-Al2O3 on an Industrial Coating Unit 257 8.4.1.6 Results of the Deposition of g-Al2O3 on an Industrial Coating Unit 258 8.4.2 Deposition Process Development of Crystalline PVD ZrO2 260 8.4.2.1 Experimental Details for the Development of t-ZrO2 260 8.4.2.2 Results and Discussion 260 8.4.2.3 Summary for the Development of t-ZrO2 263 8.4.2.4 Experimental Details on the Development of t-ZrO2 on an Industrial Coating Unit 263 8.4.2.5 Results of the Deposition of t-ZrO2 on an Industrial Coating Unit 263 8.4.3 Model and Near Application Tests 265 8.4.4 Applicability of PVD-Coated Dies in Steel Thixoforming 267 8.4.5 Perspectives for the Application of PVD-Coated Dies in Steel Thixoforming 268 8.5 Developing Al2O3 PECVD Coatings for Thixoforming Moulds 269 8.5.1 Experimental Procedure 270 8.5.2 Results and Discussion 272 8.5.2.1 Chemical Composition and Constitution 272 8.5.2.2 Film Morphology and Porosity 275 8.5.2.3 Mechanical Properties 277 8.5.3 Conclusions 280 8.6 Bulk Ceramic Forming Tools 281
Page 2: Thixoforming Semi-solid Metal Proce
Page 5 and 6: Further Reading Herlach, D. M. (ed.
Page 7 and 8: The Editors Prof. Dr. G. Hirt Insti
Page 9 and 10: VI Contents 1.3.5.2 Other Aluminium
Page 11: VIII Contents 4.6.1 Thixocasting 13
Page 15 and 16: XII Contents 9.4.1.3 Simulation Res
Page 18: Preface Semi-solid forming of metal
Page 21 and 22: XVIII List of Contributors Andreas
Page 23 and 24: XX List of Contributors Alexander S
Page 25 and 26: 2j 1 Semi-solid Forming of Aluminiu
Page 33 and 34: 10j 1 Semi-solid Forming of Alumini
Page 45 and 46: Table 1.1 Overview of semi-solid pr
Page 52: Part One Material Fundamentals of M
Page 55 and 56: 32j 2 Metallurgical Aspects of SSM
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40j 2 Metallurgical Aspects of SSM
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42j 2 Metallurgical Aspects of SSM
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44j 3 Material Aspects of Steel Thi
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Temperature (ºC) 1550 1500 1450 14
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100j 3 Material Aspects of Steel Th
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106j 4 Design of Al and Al-Li Alloy
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5 Thermochemical Simulation of Phas
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here it can be assumed that the dat
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Figure 5.2 Calculated temperature v
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Figure 5.4 Composition profiles of
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It is clear that C has by far the s
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Figure 5.7 The density of X210CrW12
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5.3 Calculations for the Bearing St
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Figure 5.11 Composition profiles of
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Figure 5.14 The density of 100Cr6.
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area which is available for heat tr
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Part Two Modelling the Flow Behavio
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170j 6 Modelling the Flow Behaviour
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7 A Physical and Micromechanical Mo
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3. Macroscopic averages or homogeni
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displacement boundary conditions or
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and liquid are both assumed to be i
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are the strain rate concentration t
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Semi-solid viscosity (Pa s) into cl
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Load (kN) strain to rupture, leadin
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Load (kN) 7 6 5 4 3 2 1 0 0 7.5 Con
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adius R radius of the spherical inc
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Part Three Tool Technologies for Fo
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242j 8 Tool Technologies for Formin
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9 Rheocasting of Aluminium Alloys a
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Figure 9.2 Processes for the semi-s
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Two Italian companies gained the fi
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9.2 SSM Casting Processesj317 For t
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Figure 9.7 Oil pump cover for Honda
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Figure 9.9 Middle temperature cours
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Figure 9.12 Components of cartridge
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Figure 9.15 Process adapted multipa
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step-shot experiments. It is also s
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Figure 9.18 (a) Meander tool for fl
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Figure 9.19 (a, b) Wear appears in
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Table 9.2 Temperature determination
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and are plausible on the left. Furt
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Figure 9.27 Development of the micr
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some places can be observed as smal
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Figure 9.31 Simulation of the metal
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Figure 9.33 So-called Constant Temp
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Figure 9.35 Comparison of the micro
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9.4 Rheoroutej347 If rounding of th
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9.4.1.2 Parameters: Cooling to the
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Figure 9.36 Results of the 2D-MICRE
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homogeneous microstructure and no d
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grain fragment density [mm -1 ] 200
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can be considered for rheocasting o
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Figure 9.44 Microstructure of Zr/Sc
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Figure 9.45 MAGMAsoft simulation: c
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The cooling to the process temperat
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D grain diameter of a circle DGM De
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27 Doppelbauer, M. (2003) Wirtschaf
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10 Thixoforging and Rheoforging of
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1970s [7]. Also, the quality of the
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10.3 Heating and Forming Operations
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With the solution of the Equations
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10.3.1.2 Modelling of Inductive Hea
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material properties have to be cons
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10.3 Heating and Forming Operations
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Figure 10.9 Experimental results, d
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Figure 10.12 Segregation in compone
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10.3.4 Thixoforging of Steel In thi
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10.3.5 Thixojoining of Steel In the
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einforcing element. The possibiliti
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Figure 10.20 The robot controller a
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Figure 10.21 Experimental results w
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Figure 10.24 Design and working pri
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The investigations show that the rh
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Figure 10.31 Scheme of the heat tra
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Table 10.2 Definition of boundary c
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Figure 10.35 Experimental and simul
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References 1 Koesling, D., Tinius,
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steel billets into the semi-solid s
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412j 11 Thixoextrusion The followin
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414j 11 Thixoextrusion channel with
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416j 11 Thixoextrusion parameter co
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418j 11 Thixoextrusion Both concept
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420j 11 Thixoextrusion should be ju
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422j 11 Thixoextrusion Figure 11.8
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424j 11 Thixoextrusion Table 11.4 C
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426j 11 Thixoextrusion Temperature
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428j 11 Thixoextrusion impacts. Ext
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432j 11 Thixoextrusion shell format
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436j 11 Thixoextrusion Table 11.6 P
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440j 11 Thixoextrusion solidificati
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442j 11 Thixoextrusion GPa pressure
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444j Index arbitrary volume element
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446j Index equilibrium tests 141 eq
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448j Index - importance 273 ion flu
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450j Index oxygen-sensitive element
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452j Index - thixoforming 241 semi-
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454j Index - high pressure 131 - sc
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Thixoforming : Semi-solid Metal Processing

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