Thixoforming : Semi-solid Metal Processing

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Table 4.5 Liquidus temperatures of alloys solidified under normal pressure and under 2000 bar, determined by means of DTA. Composition (wt%/at.%) Al Mg Li 4.5 Consideration of the Forming Pressure on Thixoalloy Developmentj129 T liquid, normal pressure ( C) T liquid, 2000 bar ( C) 98/97.8 2/2.2 0 625.4 649.6 24.2 92/93.23 6/6.75 0 615.2 626.9 11.7 90/89 10/11 0 588.1 600.9 12.8 84/82.5 16/17.5 0 541.1 562.7 21.6 99/96.2 0 1/3.8 635.7 651.9 16.2 98/92.6 0 2/7.4 627.3 620.8 6.5 97/89.3 0 3/10.7 596.9 644.3 47.4 96/86.1 0 4/13.9 590.6 628.3 37.7 97/94.1 2/2.2 1/3.8 631.3 646.1 14.8 96/90 2/2.0 2/7.3 623.5 632.5 9.0 95/87.3 2/2 3/10.7 612.4 626.5 14.1 94/84.1 2/2 4/13.9 600 623.2 23.2 93/89.8 6/6.4 1/3.8 568.7 587.2 18.5 92/86.4 6/6.3 2/7.3 601.3 611.0 9.7 91/83.2 6/6.1 3/10.7 585.6 613.5 27.9 90/80.2 6/5.9 4/13.9 573.1 598.5 25.4 89/85.6 10/10.7 1/3.7 584.9 592.1 7.2 96.4/92.3 2.1/2.2 1.46/5.4 610.4 635.7 25.3 Figure 4.15 Examples of DTA records under normal and high pressure showing differences in the thermal effect (liquidus temperature at 597 C/644 C). DT (T liquid, 2000 bar Tliquid, 1 bar) (C)
130j 4 Design of Al and Al–Li Alloys for Thixoforming ternary system Al–Li–Mg (DT ¼ 7.2–23.2 C). A systematic correlation between the pressure effect on the increase in the liquidus temperature and the structure of the corresponding binary and ternary systems could not so far be identified. 4.5.3 Effect of the Solidification Pressure on the Microstructure All samples that were solidified under a pressure of 2000 bar were very brittle, which is due to a phase modification and/or dissolution of a brittle phase on the phase boundaries. An analysis of the microstructure indicates that the morphology of the phase changes and that non-metallic contamination has accumulated at the phase boundaries of the sample that was solidified at 5–8Ks 1 under pressure (Figures 4.16 and 4.17). In the samples solidified under normal conditions, the intermetallic inclusions are uniformly finely distributed within the alloy matrix, whereas in the samples solidified under a pressure of 20 bar, these intermetallics are separated irregularly in a coarser form (Figure 4.16). In the samples solidified under a pressure of 2000 bar, the separation of the intermetallic is somewhat less again and at the phase boundaries as well as between the mix crystals the non-metallic contamination is eliminated Figure 4.16 Microstructures of Al–10Mg–1Li solidified under different pressures. Figure 4.17 Microstructures of Al–6Mg–4Li solidified under different pressures.
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Thixoforming Semi-solid Metal Proce
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Further Reading Herlach, D. M. (ed.
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The Editors Prof. Dr. G. Hirt Insti
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VI Contents 1.3.5.2 Other Aluminium
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VIII Contents 4.6.1 Thixocasting 13
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X Contents 7.4.2 Isothermal Non-ste
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XII Contents 9.4.1.3 Simulation Res
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Preface Semi-solid forming of metal
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XVIII List of Contributors Andreas
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XX List of Contributors Alexander S
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2j 1 Semi-solid Forming of Aluminiu
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10j 1 Semi-solid Forming of Alumini
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Table 1.1 Overview of semi-solid pr
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Part One Material Fundamentals of M
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32j 2 Metallurgical Aspects of SSM
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44j 3 Material Aspects of Steel Thi
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Page 129 and 130: 106j 4 Design of Al and Al-Li Alloy
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Page 170 and 171: 5 Thermochemical Simulation of Phas
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Page 174 and 175: Figure 5.2 Calculated temperature v
Page 176 and 177: Figure 5.4 Composition profiles of
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Page 180 and 181: Figure 5.7 The density of X210CrW12
Page 182 and 183: 5.3 Calculations for the Bearing St
Page 184 and 185: Figure 5.11 Composition profiles of
Page 186 and 187: Figure 5.14 The density of 100Cr6.
Page 188 and 189: area which is available for heat tr
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180j 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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