Thixoforming : Semi-solid Metal Processing

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In order to close the loop in the recycling of Al–Li residues from thixoforming, it would be necessary to process the salt slag produced. When using pure water-soluble LiCl for recycling, it is possible to treat the salt slag by means of the conventional dissolution–crystallization process that is standard within the secondary aluminium industry. This closed loop for the recycling of Al–Li residues (Figure 4.31) permits nearly complete recovery of reusable Al–Li alloys, in addition to returning the used LiCl back into the recycling process. References 1 Fehlbier, M. (2002) Verarbeitung teilfl€ussiger metallischer Werkstoffe, Dissertation, RWTH, Aachen, 9. 2 Wagener, W. and Hartmann, D. (2000) Feedstock material for semi-solid casting of magnesium. Proceedings of the 6th International Conference on Semi-solid Processing of Alloys and Composites, Turin, 301–306. 3 Flemings, M.C. (1991) Behavior of metal alloys in the semisolid state, The 1990 Edward Campell Memorial Lecture. Metallurgical Transactions A, 22A, 957–980. 4 M€uller-Sp€ath, H. (1999) Legierungs-entwicklung unter Einsatz des SSP-Verfahrens und Umsetzung intelligenter Materialkonzepte beim Thixogiessen, Dissertation, RWTH, Aachen, 5 Wan, G. and Witulski, R. (1993) Thixoforming of aluminium alloys using modified chemical grain refinement for billet production. International Conference on Aluminium Alloys: New Process Technologies, Marina di Ravenna; Brusethaug, S. and Voje, J. (2000) Manufacturing of feedstock for semi-solid processing by chemical grain refinement. Proceedings of the 6th International Conference of Semi-solid Processing of Alloys and Composites, Turin, 451–456. 6 Noll, T. (2003) Die anwendungsgerechte Weiterentwicklung des Al-Werkstoffes EN AC-AlSi7Mg0,3 (A356) mit chemischer Kornfeinung, Dissertation, RWTH, Aachen. Referencesj143 7 Hirt, G. and Sahm, P.R. (1994) M€oglichkeiten zur Produktivit€atssteigerung, Qualit€atsverbesserung und Materialeinsparung durch endabmessungsnahe Fertigung mit kombiniertenUr/Umformverfahren, EFU-Mitteilungen 1-1994. 8 Loue, W.R. (1996) Metallurgische Aspekte des Thixogiessens der Aluminiumlegierungen AlSi7Mg0,3 und AlSi7Mg0,6. Giesserei-Praxis, (13/14), 251–260. 9 Decker, R. (1990) Casting semi-solids by thixomolding, Foundry Focus, Autumn/ Winter, 22–23. 10 Decker, R. and Carnahan, R.D. (1991) Thixomolding. Advanced Materials Technology, 8, 174–179. 11 Dworog, A. et al. (2000) Formf€ullvorg€ange beim Magnesiumspritzgiessen, 8. Magnesium Abnehmer Seminar, Aalen, 14–15 June 2000. 12 Decker, R.F. and Carnahan, R.D. (1991) Thixomolding, Thixomat Inc., Ann Arbor, MI, 47th Mg Conference, 106–116. 13 Gullo, G.C. (2001) Thixotrope Formgebung von Leichtmetallen – neue Legierungen und Konzepte, Dissertation, ETH Z€urich, Dissertation ETH Nr 14154. 14 Prikhodovsky, S. (2000) Modellierung von Reifungsprozessen und Anwendung auf das Thixoforming, Deutsche Dissertation 15 Steinhoff, K., Gullo, G.C., Kopp, R. and Uggowitzer, P.J. (2000) A new integrated production concept for semi-solid processing of high quality Al products, Proceedings of the 6th International
144j 4 Design of Al and Al–Li Alloys for Thixoforming Conference on Semi-solid Processing of Alloys and Composites, 27–29 September 2000, Turin, Edimet, Brescia, 121–127. 16 Harris, S.J., Noble, B. and Dinsdale, K. (1983) Proceedings of the 2nd International Conference on Aluminium–Lithium Alloys II (eds T.H. Sanders and E.A. Starke), TMS, Warrendale, PA, 219. 17 Kammer, C. (1995) Aluminium- Taschenbuch, Band 1, Grundlagen und Werkstoffe, 15. Auflage, Aluminium- Verlag, D€usseldorf, 303. 18 Davis, J.R. (1998) In Davis et al. (eds), ASM Specialty Handbook, Aluminum and Lithium Alloys, ASM International, Materials Park, OH, 19 Starke, E.A. and Sanders, T.H., Jr (1986) Proceedings of the 1st International Conference on Aluminium Alloys: Their Physical and Mechanical Properties. 20 Bick, M. and Markwoth, M. (1980) Thoughts on the removal of lithium from primary aluminium and experiments to carry out the process on a technical scale. Metall, 34 (12), 1095–1098. 21 Bofarini, C. (1991) Prozessentwicklung des Feingiessens von Al–Li Legierungen sowie Untersuchungen ihrer giesstechnischen und mechanischen Eigenschaften Giessereiforschung, 43, (2). 22 Polmear, I.J. (1989) Light Alloys – Metallurgy of the Light Metals, Edward Arnold, London, pp. 130–132. 23 Vekateswara, R., Yu, W. and Ritchie, R.B. (1988) Metallurgical Transactions A, 19, 563. 24 Miller, W.S., White, J. and Eloyd, D.J. (1987) Proceedings of the 4th International Conference on Aluminium–Lithium Alloys IV (eds G. Champier, B. Dubost, D. Miannay and E. Sabetay), Paris, J. de Phys Colloque, 48, C3, 139. 25 Webster, D. (1994) Aluminium–lithium alloys, the next generation. Advances in Materials and Processes, 145, (5), 18–24. 26 Sweet, E.D. et al. (1994) Proceedings of the 4th International Conference on Al Alloys, Georgia Institute of Technology, Atlanta, GA, 231. 27 Kopp, R. et al. Sonderforschungsbereich SFB 289: Formgebung metallischer Werkstoffe im teilerstarrten Zustand und deren Eigenschaften, Arbeits- und Ergebnisbericht 2002/2003/2004 f€ur die Deutsche Forschungsgemeinschaft DFG, 54–56. 28 Balitchev, E. (2004) Thermochemische und kinetische Modellierung zur Legierungsauswahl mehrphasiger Systeme f€ur das Thixoforming und zur Optimierung ihrer Formgebungsprozesse, Dissertation, RWTH, Aachen. 29 Balitchev, E., Hallstedt, B. and Neusch€utz, D. (2005) Thermodynamic criteria for the selection of alloys suitable for semi-solid processing. Steel Research International, 76 (2/3), 92–98. 30 Fridlyander,I.N.,Rokhlin,L.L.,Dobatkina, T.V. and Nikitina, N.I. (1993) Phase equilibria in aluminium alloys containing lithium. Metallovedenie i Termicheskaya Obrabotka Metallov, (10), 16–19 (in Russian). 31 Hemminger, W. and Cammenga, H. (1989) Methoden der Thermischen Analyse, Springer, Berlin. 32 H€ohne, G., Hemminger, W. and Flammersheim, H.-J. (1996) Differential Scanning Calorimetry – an Introduction for Practioners, Springer, Berlin. 33 Kopp, R. et al. (2008) Sonderforschungsbereich SFB 289: Formgebung metallischer Werkstoffe im teilerstarrten Zustand und deren Eigenschaften, Arbeits- und Ergebnisbericht 2002/2003/2004 f€ur die Deutsche Forschungsgemeinschaft DFG, 165. 34 Sauermann, R., Friedrich, B., Grimmig, T., B€unck, M. and B€uhrig-Polazcek, A. Development of Al–Li alloys processed by the Rheo Container Process, Proceedings of the 9th International Conference on Semi-solid Processing of Alloys and Composites, Busan, Korea. 35 Sauermann, R., Friedrich, B., P€uttgen, W., Bleck, W., Balitchev, E., Hallstedt, B., Schneider, J.M., Bramann, H., B€uhrig-Polaczek, A. and Uggowitzer, P.J. (2004) Aluminium–lithium alloy
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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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Temperature (ºC) 1550 1500 1450 14
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194j 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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