Thixoforming : Semi-solid Metal Processing

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adius R radius of the spherical inclusion RVE representative volume element Sij deviatoric stress tensor T s , T l strain rate concentration tensors (s, solid; l, liquid) V volume References 1 Flemings, M.C. (1991) Behaviour of metal alloys in the semi-solid state. Metallurgical Transactions. A, 22, 957–981. 2 Loue, W.R., Landkroon, S. and Kool, W.H. (1992) Rheology of partially solidified AlSi7Mg0.3 and the influence of SiC additions. Materials Science and Engineering A – Structural Materials Properties Microstructure and Processing, 151, 255–262. 3 Quaak, C.J. (1994) Properties of semi-solid aluminium matrix composites. Materials Science and Engineering A – Structural Materials Properties Microstructure and Processing, 188, 277–282. 4 McLelland, A.R.A., Henderson, N.G., Atkinson, H.V. and Kirkwood, D.H. (1997) Anomalous rheological behaviour of semi-solid alloy slurries at low shear rates. Materials Science and Engineering A – Structural Materials Properties Microstructure and Processing, 232, 110–118. 5 Modigell, M. and Koke, J. (2001) Rheological modelling on semi-solid metal alloys and simulation of thixocasting processes. Journal of Material Processing Technology, 111, 53–58. 6 Koke, J. and Modigell, M. (2003) Flow behaviour of semi-solid metal alloys. Journal of Non-Newtonian Fluid Mechanics, 112, 141–160. 7 Atkinson, H.V. (2005) Modelling the semi-solid processing of metallic alloys. Progress in Materials Science, 50, 341–412. 8 Eshelby, J.D. (1957) The determination of the elastic field of an ellipsoidal Referencesj237 inclusion and related problems. Proceedings of the Royal Society London, A241, 376–396. 9 Kr€oner, E. (1958) Berechnung der elastischen konstanten des Vielkristalls aus den Konstanten des Einskristalls. Zeitschrift f€ur Physik, 151, 504–518. 10 Kr€oner, E. (1961) Z€ur plastischen Verformung des Vielkristalls. Acta Metallurgica, 9, 155–161. 11 Mura, T. (1987) Micromechanics of Defects in Solids, Martinus, NiJhoff Publishers. 12 Zaoui, A. (2001) Plasticite: approches en champs moyens, in Homogeneisation en Mecanique des Materiaux (Vol. 2): Comportements Non Lineaires et Problemes Ouverts (eds M. Bornert, T. Bretheau and P. Gilormini), Hermes, Paris, Chapter I, pp. 17–44. 13 Doherty, R., Lee, H. and Feest, E. (1984) Microstructure of stir-cast metal. Materials Science and Engineering, 65, 181–189. 14 Kumar, P., Martin, C. and Brown, S.B. (1993) Shear rate thickening behaviour of semi-solid slurries. Metallurgical Transactions A, 24, 1107–1116. 15 Seconde, I.F. and Suery, M. (1984) Effect of solidification conditions on deformation behaviour of semi-solid Sn–Pb alloys. Journal of Materials Science, 19, 3995–4006. 16 Joly, P.A. and Mehrabian, R. (1976) The rheology of a partially solid alloy. Journal of Materials Science, 11, 1393–1418. 17 Kumar, P., Martin, C. and Brown, S.B. (1994) Constitutive modelling and characterization of the flow behaviour of semi-solid metal alloy
238j 7 A Physical and Micromechanical Model for Semi-solid Behaviour slurries – I. The flow response. Acta Metallurgica and Materialia, 42, 3595–3602. 18 Martin, C., Kumar, P. and Brown, S.B. (1994) Constitutive modelling and characterization of the flow behaviour of semi-solid matal alloy slurries– II. Structural evolution under shear deformation. Acta Metallurgica and Materialia, 42, 3595–3602. 19 Zavaliangos, A. and Lawley, A. (1995) Numerical simulation of thixoforming. Journal of Materials Engineering and Performance, 4, 40–47. 20 Wahlen, A. (2000) Modelling the thixotropic flow behaviour of semi-solid aluminium alloys, in Proceedings of the 6th International Conference on Semisolid Processing of Alloys and Composites (eds G.L. Chiarmetta and M. Rosso), Turin, 27–29 September 2000, pp. 565–570. 21 Kirkwood, D.H., Ward, P.J., Barkhudarov, M., Chin, S.B., Atkinson, H.V. and Liu, T.Y. (2000) An initial assessment of the flow-3D thixotropic model, in Proceedings of the 6th International Conference on Semisolid Processing of Alloys and Composites (eds G.L. Chiarmetta and M. Rosso), Turin, 27–29 September 2000, pp. 545–551. 22 Burgos, G.R., Alexandrou, A.N. and Entov, V. (2001) Thixotropic rheology of semisolid metal suspensions. Journal of Materials Processing Technology, 111, 164–176. 23 De Gennes, P.G. (1979) Scaling Concepts in Polymer Physics, Cornell University Press, Ithaca, NY. 24 Stauffer, D. (1985) Introduction to Percolation Theory, Taylor and Francis, London. 25 Favier, V., Rouff, C., Bigot, R., Berveiller, M. and Robelet, M. (2004) Micro–macro modelling of the isothermal steady-state behaviour of semi-solids. International Journal of Forming Processes, 7, 177–194. 26 Berveiller, M. and Zaoui, A. (1981) A simplified self-consistent scheme for the plasticity of two-phase metals. Research Mechanica Letters, 1, 119–124. 27 Christensen, R.M. and Lo, K.H. (1979) Solutions for effective shear properties in three-phase sphere and cylinder models. Journal of Mechanics and Physics of Solids, 27, 315–330. 28 Cherkaoui, M., Sabar, H. and Berveiller, M. (1994) Micromechanical approach of the coated inclusion problem and applications to composite materials. Journal of Engineering Materials and Technology, 116, 274–278. 29 Laxmanan, V. and Flemings, M. (1980) Deformation of semi-solid Sn–15 pct Pb alloy. Metallurgical Transactions A, 11, 1927–1937. 30 Ghosh, D., Fan, R. and Vanschilt, C. (1994) Thixotropic properties of semi-solid magnesium alloys AZ91D and AM50, in Proceedings of the 3rd International Conference on Semi-solid Processing of Alloys and Composites (ed. M. Kiuchi), Tokyo, 13–15 June 1994, pp. 85–94. 31 Lucas, L.D. (1984) Viscosite des principaux metaux et metallo€ıdes, Techniques de l Ingenieur, MB1 M66. 32 Loue, W.R. Landkroon, S., Kool, W.H. (1992) Rheology of Partially solidified AlSi7Mg0.3 and the influence of SiC additions. Materials Science and Engineering, A151, 255–262. 33 Kirkwood, D.H. (1994) Semi-solid metal processing. International Material Reviews, 39, 173–189. 34 Liu, T.Y., Atkinson, H.V., Kapranos, P., Kirkwood, D.H. and Hogg, S.C. (2003) Rapid compression of aluminum alloys and its relationship to thixoformability. Metallurgical Materials Transactions A, 34, 1545–1554. 35 Cezard, P., Bigot, R., Favier, V. and Robelet, M. (2006) Thixoforming of steel – influence of thermal parameters. Solid State Phenomena, 116–117, 721–724. 36 Cezard, P., Favier, V., Balan, T., Bigot, R. and Berveiller, M. (2005) Simulation of semi-solid thixoforging using a micro–macro constitutive equation. Computational Materials Science, 32, 323–328.
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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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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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Page 209 and 210: 186j 6 Modelling the Flow Behaviour
Page 244 and 245: 7 A Physical and Micromechanical Mo
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288j 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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