Thixoforming : Semi-solid Metal Processing

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Liudmila Khizhnyakova RWTH Aachen University Institute of Metal Forming Intzestrasse 10 52072 Aachen Germany Frederik Knauf RWTH Aachen University Institute of Metal Forming Intzestrasse 10 52072 Aachen Germany Reiner Kopp RWTH Aachen University Institute of Metal Forming 52072 Aachen Germany Fabian Küthe RWTH Aachen University Foundry Institute Intzestrasse 5 52072 Aachen Germany Erich Lugscheider RWTH Aachen University Institut für Oberflächentechnik Templergraben 55 52056 Aachen Germany Heike Meuser V & M Deutschland GmbH Schützenstrasse 124 45476 Mülheim a. d. Ruhr Germany Michael Modigell RWTH Aachen University Aachener Verfahrenstechnik Turmstrasse 46 52056 Aachen Germany Simon Münstermann RWTH Aachen University Institut für Gesteinshüttenkunde Mauerstraße 5 52056 Aachen Germany Tony Noll RWTH Aachen University IME – Process Metallurgy and Metal Recycling Intzestrasse 3 52072 Aachen Germany Lars Pape RWTH Aachen University Aachener Verfahrenstechnik Turmstrasse 46 52056 Aachen Germany Wolfgang Püttgen McKinsey & Company Königsallee 60c 40026 Düsseldorf Germany Roger Sauermann RWTH Aachen University Process Metallurgy and Metal Recycling Intzestrasse 3 52072 Aachen Germany Jochen M. Schneider RWTH Aachen University Materials Chemistry Kopernikusstrasse 16 52074 Aachen Germany List of Contributors XIX
XX List of Contributors Alexander Schönbohm RWTH Aachen University Institute of Automatic Control Steinbachstraße 54 52056 Aachen Germany Ingold Seidl RWTH Aachen University Institute of Metal Forming Intzestrasse 10 52072 Aachen Germany Hideki Shimahara RWTH Aachen University Institute of Metal Forming Intzestrasse 10 52072 Aachen Germany Rainer Telle RWTH Aachen University Mauerstraße 5 Institut für Gesteinshüttenkunde 52056 Aachen Germany Peter J. Uggowitzer ETH Zurich Department of Materials Laboratory of Metal Physics and Technology 8093 Zurich Switzerland Dirk I. Uhlenhaut ETH Zurich Department of Materials Laboratory of Metal Physics and Technology 8093 Zurich Switzerland Ksenija Vasilić RWTH Aachen University Aachener Verfahrenstechnik Turmstrasse 46 52056 Aachen Germany
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 and 14: X Contents 7.4.2 Isothermal Non-ste
Page 15 and 16: XII Contents 9.4.1.3 Simulation Res
Page 18: Preface Semi-solid forming of metal
Page 21: XVIII List of Contributors Andreas
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
Page 67 and 68: 44j 3 Material Aspects of Steel Thi
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50j 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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