Thixoforming : Semi-solid Metal Processing

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8.6.1 Candidate Die Materials 281 8.6.2 Ceramic Die Concepts for Steel Thixoforming 283 8.6.3 Conventionally Heated Tools 285 8.6.3.1 Characteristic Load Profile and Die Material Selection 285 8.6.3.2 Corrosion Experiments and Forming Series 286 8.6.3.3 Corrosion Mechanisms and Forming Performance 288 8.6.3.4 Applicability of Silicon Nitride Dies in Steel Thixoforming 292 8.6.4 Self-heating Dies 294 8.6.4.1 Die Materials and Tool Characteristics 294 8.6.4.2 Tool Design and Construction 296 8.6.4.3 Forming Performance and Wear Resistance 298 8.6.4.4 Applicability of Self-heating Ceramic Dies for Steel Thixoforming 299 8.6.5 Perspectives for the Application of Bulk Ceramic Dies in Steel Thixoforming 300 8.7 Conclusions and Perspectives 301 References 303 Part Four Forming of Semi-solid Metals 309 9 Rheocasting of Aluminium Alloys and Thixocasting of Steels 311 Matthias Bünck, Fabian Küthe, and Andreas Bührig-Polaczek 9.1 Casting of Semi-solid Slurries 311 9.2 SSM Casting Processes 312 9.2.1 Developmental History of the Part Liquid Aluminium Processing 314 9.3 Thixocasting of Steel Alloys 319 9.3.1 Inductive Heating for Steels: Adaptation and Process Control 319 9.3.2 Casting Technology and Systems 323 9.3.2.1 Systems Engineering for Thixo- and Rheoprocesses 323 9.3.2.2 Process-adapted Shot Chamber System 323 9.3.2.3 Technological Design Layout 325 9.3.3 Model Tests 326 9.3.3.1 Investigations on Mould Filling Behaviour (Step Die) 327 9.3.3.2 Determination of Flow Length Capabilities (Meander Die) 328 9.3.3.3 Examinations of the Wear Behaviour of the Form Tools 330 9.3.4 Demonstrators and Real Parts 335 9.3.4.1 Impeller 335 9.3.4.2 Kitchen and Diving Knives 337 9.4 Rheoroute 342 9.4.1 Cooling Channel Process 343 9.4.1.1 Parameters: Seed Crystal Multiplication on the Cooling Channel 344 9.4.1.2 Parameters: Cooling to the Process Temperature 349 Contents XI
XII Contents 9.4.1.3 Simulation Results 350 9.4.1.4 Oxidation 355 9.4.1.5 Summary 355 9.4.2 Rheo Container Process (RCP) 355 9.4.3 Demonstrator: Tie Rod 357 9.4.3.1 Thixocasting: A356 358 9.4.3.2 Aluminium–Lithium Alloy 358 9.4.3.3 RCP: AlLi2.1Mg5.5 358 9.4.3.4 Thixocasting of Tailored AlLi2.1Mg5.5 360 9.4.3.5 Cooling Channel Process: A356 362 9.5 Assessment and Outlook 364 9.5.1 Rheo Processes 364 9.5.2 Thixocasting of Steels 364 References 365 10 Thixoforging and Rheoforging of Steel and Aluminium Alloys 369 Gerhard Hirt, René Baadjou, Frederik Knauf, Ingold Seidl, Hideki Shimahara, Dirk Abel, Reiner Kopp, Rainer Gasper, and Alexander Schönbohm 10.1 Introduction 369 10.2 Forging in the Semi-solid State 371 10.3 Heating and Forming Operations 373 10.3.1 Induction Process 373 10.3.1.1 Heat Transfer Equations 375 10.3.1.2 Modelling of Inductive Heating with the Finite Difference Method (FDM) 377 10.3.1.3 Control of Inductive Heating 377 10.3.2 Thixoforging and Thixo Lateral Extrusion of Aluminium 383 10.3.3 Thixo Lateral Extrusion of Steel 385 10.3.4 Thixoforging of Steel 387 10.3.5 Thixojoining of Steel 389 10.3.6 Automated Thixoforming – Thixo Cell 391 10.3.6.1 Feedstock Magazine and Unloading Unit 391 10.3.6.2 Robot with Gripper 392 10.3.6.3 Forming Aggregates 392 10.3.6.4 Sequence Control of the Plant 392 10.3.6.5 Master Process Controller 392 10.3.6.6 Control of the Forming Process 394 10.3.7 Rheoforging of Steel 395 10.4 Simulation of the Thixoforming Process 399 10.4.1 Material Properties and Boundary Conditions 399 10.4.1.1 Radiation 399 10.4.1.2 Heat Transfer Coefficient Between Workpiece and Die 400 10.4.2 Simulation of a Thixoforged Component 401
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 and 12: VIII Contents 4.6.1 Thixocasting 13
Page 13: X Contents 7.4.2 Isothermal Non-ste
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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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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