Thixoforming : Semi-solid Metal Processing

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Figure 6.47 Variation of (a) temperature and solid fraction and (b) grain density at a middle point and outlet point over the channel versus flow time. 6.3 Simulation of Cooling Channelj213 Validation experiments were conducted under the same conditions as simulation. Figure 6.49 shows the resulting microstructure after holding for 120 s in the container. The average measured temperature inside the container after 120 s was 863.60 K while the computed value in Figure 6.48a lies between 864.88 and 867.27 K, which is an indicator of the good agreement of heat flow models and boundary condition application. On the other hand, the experimental grain density (1.731 10 12 m 3 ) and the average grain size (0.0558 mm) deviated from the
214j 6 Modelling the Flow Behaviour of Semi-solid Metal Alloys Figure 6.48 (a) Computed cooling curves inside the container for in A356 aluminium alloy; (b, c) grain density and grain size versus solidification time. computed values (4.37 10 10 m 3 and 0.21 mm, respectively). The most probable reason is the grain multiplication due to continuous cooling/shearing of the solidifying particles over the channel. This effect was not considered in MeSES. The calculated local shear rate values (dv/dy) near CP2 at 2.3 s are shown in Figure 6.50. The shear rate can reach more than 630 s 1 . The grain nucleation model implemented in MeSES is based on cooling rate and demonstrated good results [44] in the absence of shear.
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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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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
Page 186 and 187: Figure 5.14 The density of 100Cr6.
Page 188 and 189: area which is available for heat tr
Page 190: Part Two Modelling the Flow Behavio
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Page 244 and 245: 7 A Physical and Micromechanical Mo
Page 246 and 247: 3. Macroscopic averages or homogeni
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Page 250 and 251: and liquid are both assumed to be i
Page 252 and 253: are the strain rate concentration t
Page 254 and 255: Semi-solid viscosity (Pa s) into cl
Page 256 and 257: Load (kN) strain to rupture, leadin
Page 258 and 259: Load (kN) 7 6 5 4 3 2 1 0 0 7.5 Con
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Page 262: Part Three Tool Technologies for Fo
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264j 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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