Thixoforming : Semi-solid Metal Processing

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Figure 9.2 Processes for the semi-solid working of metal alloys. When the material reaches the desired temperature, the mould is lightly inductively heated, to melt the material in contact with the mould wall and thus facilitate the extraction of the billet. The newly developed rheo-container process (RCP) (Figure 9.3) for light metal alloys should solve the problem of transferring the semi-solid billet from the preparation mould to the shot sleeve of a modified HPDC machine [9]. The melt is directly poured into a disposable container. When the metal reaches the desired thixotropic conditions, the slurry and container are pressed in the HPDC machine. The metal flows into the cavity of the mould while the container remains in the biscuit. Because of this, the use of specially designed moulds for the cooling of the melt and eventual reheating of a pre-material is not necessary. Figure 9.3 New rheocasting process (RCP) [8]. 9.2 SSM Casting Processesj313
314j 9 Rheocasting of Aluminium Alloys and Thixocasting of Steels Another interesting method is the so-called cooling channel process [10], which will be presented in Section 9.4.1. The melt is poured on to an inclined channel just above liquidus and caught in an isolated ceramic container. The metal flow induces the heterogeneous nucleation of solid particles and the retarded cooling in the container promotes globular growth of the solid particles. After reaching the desired solid fraction, the slurry is tilted in the shot sleeve of the HPDC machine and formed. More complex conditions exist during the one-step process of semi-solid injection moulding or thixomoulding (Figure 9.2) where feedstock particulates of a specific nature are subjected to the simultaneous influence of the heat supplied from an external source and shear force imposed by the injection screw in a machine very similar to those used for the injection of thermoplastics [11]. This process is especially effective for processing magnesium alloys. 9.2.1 Developmental History of the Part Liquid Aluminium Processing Numerous companies have utilized the advantages of the processing of semi-solid materials for developing SSM technology since the 1990s. Table 9.1 gives the most important manufacturers of pre-material, users and international large academic facilities [6]. Table 9.1 Relevant manufacturer and R&D facilities for Al thixocasting. Pre-material Producer R&D 1) Alcoa (Alumax) (Canada) AEMP (USA) Aachen RWTH (Germany) Algroup Alusuisse (Switzerland) Algroup Alusuisse (CH) Brunel University (UK) Hertwich Engineering (Austria) Aluthix (The Netherlands) ETH Z€urich (Switzerland) NorskHydro [F&E] (Norway) Audi [F&E 2) ] (Germany) FhG Bremen (Germany) Northwest (USA) B€uhler (Switzerland) INPG Grenoble (France) Ormet (USA) DaimlerChrysler [F&E 2) ] (Germany) LK Ranshofen (Austria) Pechiney (France) Form Cast (USA) MIT (USA) SAG Thixalloy (Austria) Honda Engineering (Japan) Osaka University (Japan) Hot Metal Molding (USA) Pusan University (South Korea) Madison Kipp (USA) SINTEF (Norway) SAG (Austria) (Germany) Ancona University (Italy) Stampal (Italy) Sheffield University (UK) UBE Industries (Japan) Stuttgart University (Germany) Volkswagen [F&E 2) ] (Germany) Weber & Broutin (Italy) WPI (USA) 1) Research & Development. 2) Forschung & Entwidclung.
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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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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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Page 340 and 341: 9.2 SSM Casting Processesj317 For t
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Page 356 and 357: Table 9.2 Temperature determination
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Page 364 and 365: Figure 9.31 Simulation of the metal
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Page 370 and 371: 9.4 Rheoroutej347 If rounding of th
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Page 374 and 375: Figure 9.36 Results of the 2D-MICRE
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Page 382 and 383: Figure 9.44 Microstructure of Zr/Sc
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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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