Thixoforming : Semi-solid Metal Processing

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The EDS graph clearly shows the zirconium reflex of the coating and the tungsten reflex of the interlayer. Traces of iron can also be detected. The Al2O3-coated plates show more iron build-up than the ZrO2-coated plates. However, both ceramic PVD coatings show no visible signs of serve erosion or abrasion. These investigations have shown that both coating candidates are suitable for industrial forming operations. 8.4.4 Applicability of PVD-Coated Dies in Steel Thixoforming 8.4 Multifunctional PVD Composites for Thixoforming Mouldsj267 Thixoforging, -casting and -extrusion dies are coated with application of the parameters determined on the above-mentioned samples. Prior to deposition, the tool substrates are hardened to 54 HRC and subsequently cleaned ultrasonically with industrial cleaning equipment containing surfactant solutions and rinsed with deionized water. Finally, the dies are dried in hot air. During deposition, the dies are moved in a planetary motion to ensure an even film distribution. Figure 8.23 shows (a) a coated thixoextrusion die and (b) three coated inserts for the thixocasting process. For the bilayer coating system, the TiAlN interlayer is 5.2 and 2.3 mm for the g-Al2O3 top coat. The forming experiments on the different coated tools were carried out at the IBF and GI (see also Chapter 9). The coated parts show good performance during the thixoforming tests. The different coated parts were now analysed for phase stability with EDS, SEM and XRD. For the extrusion dies, the coatings showed excellent performance so far in the first experiments [38] (Figure 8.24). The coated samples were also investigated in the thixoforging process. Figure 8.25 shows the results of the forming experiments carried out at the IBF with the hybrid tool concept. A schematic drawing of the concept is shown in Figure 8.5. The upper dies are coated with g-Al 2O 3 and t-ZrO 2 PVD coatings. For the examination, a g-Al 2O 3 coated insert was analysed after 33 forming cycles using X210CrW12 as forming material. The SEM and EDS investigations showed that there are several traces of iron in the centre of the coated tool after the forming experiments. The coating is still present here; this can be seen by the aluminium and oxygen peaks. Also, the coating remains stable around the edges. Small pieces of iron can be detected here. No traces of iron can be seen in the inner area. Figure 8.23 PVD coated hot working steel and TZM dies with TiAlN/g-Al2O3.
268j 8 Tool Technologies for Forming of Semi-solid Metals Figure 8.24 SEM and EDS analysis of the used coated extrusion segment. 8.4.5 Perspectives for the Application of PVD-Coated Dies in Steel Thixoforming Competitive solutions for tools have to provide high mechanical strength at high temperatures, good resistance against thermal shock and the ability to withstand the attack of the semi-solid material. The thixoforming experiments showed promising results for the developed tooling coating concepts and materials. Both systems, Figure 8.25 Coated tool after 33 forming cycles and SEM and EDS analysis.
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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 244 and 245: 7 A Physical and Micromechanical Mo
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Page 334 and 335: 9 Rheocasting of Aluminium Alloys a
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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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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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