Thixoforming : Semi-solid Metal Processing

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Table 9.2 Temperature determination with and without correction of the emission coefficient. Unit Before determination of e After determination of e Emission Min. ( C) Max. ( C) Av. ( C) Emission 9.3 Thixocasting of Steel Alloysj333 Min. ( C) Max. ( C) Av. ( C) 1.2343 1 84.2 160.8 114.1 0.506 127.5 243.5 173.1 TZM Al2O3 IOT 1 152 185.2 162.6 0.711 187.2 227.9 200.2 TZM Al 2O 3 MCh 1 95.1 147.7 132.7 0.729 115.4 179.1 161 TZM Al2O3 IOT 1 97 113.7 108 0.678 123 144.3 137.1 1.2343 Al 2O 3IOT 1 102.1 189.8 169.3 0.506 155 287 256.2 1.2999 Al2O3 IOT 1 135 171.2 153.8 0.742 162.1 205.3 184.5 1.2999 Al 2O 3 IOT 1 100.3 160 137.9 0.762 118.4 188.9 162.8 1.2999 Al2O3 IOT 1 104.8 134.8 123.7 0.725 127.7 164.1 150.6 1.2343 1 66.5 107.6 75 0.506 100 163.3 113.3 CuCoBe 1 40.8 64.5 48.3 0.389 67.3 113.5 82.4 TZM multilayer MCh 1 62.3 144.9 129.5 0.788 71.5 167.6 149.8 Si3N4 massive 1 94.3 121.7 111.2 0.691 118.2 152.6 139.5 1.2343 1 86.7 195.5 167.9 0.506 131.4 295.6 254.1 Si3N4 soldered 1 165.2 259.1 228.4 0.977 167.6 262.8 231.6 HSS 1 45.5 120 63.9 0.469 68.9 190.6 100.1 1.2343 1 66.3 118.8 94.6 0.506 99.6 180.3 143.5 Figure 9.22 shows a thermograph of a component approximately 5 s after the conclusion of the filling of the form. The biscuit itself is no longer very hot at 520 C because it is only a few millimetres thick, which considerably increases the process reliability. The area of the oxide restrainer belongs, at over 730 C, to the hottest zones. The part does not show any rips which could be recognized as fine, bright lines. It becomes visible that the different component thicknesses of 10 mm (in step 1) and 5 mm cause a difference in temperature on the surface of over 250 C. The temperature seems to rise within 5 mm of the plate end. This can be explained by a transport of ceramic mould release agents by the flowing front and the consequent increase in the emission coefficient. The thermography of the tool surfaces directly after the removal of the component shows clear differences for the single tool areas and materials. The centrally inrushing material leads to strong heating of the runner and particularly the exposed corners (315 C). The redirection of the vertically flowing SSM makes a strong energy contribution to the surfaces above and below the gating. The influence of the different tool materials can be clearly recognized. The silicon nitride ceramic shows the highest temperature, over 300 C. Against this, the copper insert on the other side is at only 80 C because of its extremely high heat conductivity. The tests showed that the strength of the lowmelting copper-based material is great enough for that process because the heat conductivity is improved by around a factor of 10 compared with steels of the same specific heat capacity.
334j 9 Rheocasting of Aluminium Alloys and Thixocasting of Steels Figure 9.22 Thermograph of the plate sample with overflows and the oxide restrainer. The first of the four inserts are manufactured from hot work tool steel. The temperatures of the inserts seem on the left and on the right differ strongly in the thermal imaging (Figure 9.23). With different emission coefficients of 0.85 (Al2O3 coating) and 0.506 (steel ground), the temperatures coincide with 256.2 and 254.1 C Figure 9.23 Thermograph of the moving half of plate sample mould; for materials division, see Figure 9.21
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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 305 and 306: 282j 8 Tool Technologies for Formin
Page 334 and 335: 9 Rheocasting of Aluminium Alloys a
Page 336 and 337: Figure 9.2 Processes for the semi-s
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Page 340 and 341: 9.2 SSM Casting Processesj317 For t
Page 342 and 343: Figure 9.7 Oil pump cover for Honda
Page 344 and 345: Figure 9.9 Middle temperature cours
Page 346 and 347: Figure 9.12 Components of cartridge
Page 348 and 349: Figure 9.15 Process adapted multipa
Page 350 and 351: step-shot experiments. It is also s
Page 352 and 353: Figure 9.18 (a) Meander tool for fl
Page 354 and 355: Figure 9.19 (a, b) Wear appears in
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Page 360 and 361: Figure 9.27 Development of the micr
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Page 364 and 365: Figure 9.31 Simulation of the metal
Page 366 and 367: Figure 9.33 So-called Constant Temp
Page 368 and 369: Figure 9.35 Comparison of the micro
Page 370 and 371: 9.4 Rheoroutej347 If rounding of th
Page 372 and 373: 9.4.1.2 Parameters: Cooling to the
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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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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