Thixoforming : Semi-solid Metal Processing

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Figure 6.49 Microstructure of A356 feedstock produced by the cooling channel after holding for 120 s in the container. Figure 6.50 The computed shear rate (s 1 ) in the melt over the channel near CP2 at 2.3 s. 6.3.4 Summary The MeSES code was applied successfully to simulate the formation of semi-solid feedstock using the cooling channel process. The models implemented within the code exhibited a satisfactory response to the variation of different process parameters. The results agree with expectations and have the same trend as the experimental results in the literature [37, 46]. After application of the experimentally determined grain nucleation parameters, the results were improved and became more reliable in the absence of melt convection and shear. In the presence of shear flow, the grain density and grain diameter values deviated from the experiments. Further study of the effect of shear and vigorous melt convection during continuous cooling of molten alloys on grain nucleation and multiplication is highly recommended. List of Symbols T _ v _ tensor vector 6.3 Simulation of Cooling Channelj215
216j 6 Modelling the Flow Behaviour of Semi-solid Metal Alloys u, T scalar h viscosity [Pa s] t shear stress [Pa] g_ shear rate [s 1 ] k consistency factor [Pa s n ] n power law coefficient (flow exponent) t0 yield stress; zero shear stress [Pa] t¥ infinite shear stress [Pa] h0 zero shear viscosity [Pas] h¥ infinite shear viscosity [Pa s] fS solid fraction (volume fraction solid) k degree of agglomeration ke degree of agglomeration equilibrium II second invariant S_ stress tensor D_ deformation rate tensor u_ velocity vector uS solid velocity [m s 1 ] uL liquid velocity [m s 1 ] subscript S solid phase subscript L liquid phase subscript B bulk phase c rate constant for k tw wall shear stress [Pa] Dp pressure drop [Pa] L length [m] a volumetric flow rate [m 3 s 1 ] H height [m] W width [m] C diameter [m] R radius [m] r radial coordinate [m] hap apparent viscosity [Pa s] n rotational speed [s 1 ] w angular velocity [rad s 1 ] G00 loss modulus [Pa] G0 storage modulus [Pa] S_ stress tensor Sij components of the stress tensor [Pa] e_ strain tensor eij _e components of the strain tensor strain rate tensor _e ij components of the strain rate tensor [s 1 ]
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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
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Figure 5.14 The density of 100Cr6.
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Page 190: Part Two Modelling the Flow Behavio
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Page 246 and 247: 3. Macroscopic averages or homogeni
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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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266j 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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