Thixoforming : Semi-solid Metal Processing

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steel billets into the semi-solid state based on pyrometer measurements, Proceedings of the 9th International Conference on Semi-solid Processing of Alloys and Composites, Busan, Korea; Solid State Phenomena, Vols 116–117, Trans Tech Publications. 40 Kopp, R., Neudenberger, D. and Winning, G. (2000) Optimisation of the forming variants forging and transverse impact extrusion with alloys in the semi-solid state, Proceedings of the 6th International Conference on Alloys and Composites, 6th SSM Conference, Turin, pp. 295–300. 41 Wang, K., Hirt, G. and Kopp, R. (2006) Investigation on forming defects during thixoforging of aluminum alloy AlSi7Mg. Advanced Engineering Materials, 8 (8), 724–729. 42 Kallweit, J. (2003) Entwicklung von Formgebungsstrategien zum Thixoforming von Stahl und zum F€ugen im thixotropen Zustand, Dissertation RWTH Aachen. 43 Lemmen, M. and Wey, T. (1998) Flachheitsbasierte Regelung eines hydraulischen Differentialzylinders, VDI- Berichte 1397, VDI-Verlag, pp. 869–876. 44 Gasper, R., Sch€onbohm, A. and Abel, D. (2007) Flachheitsbasierte Vorsteuerung eines hydraulischen Differentialzylinders beim Thixoforming, GMA-Kongress, Baden-Baden, 12–13 June 2007, VDI- Berichte 1980, VDI-Verlag, pp. 487–496. 45 Seidl, I. and Kopp, R. (2004) Semi-solid rheoforging of steel. Steel Research International, 75 (8/9), 545. 46 Ramadan, M., Takita, M. and Nomura, H. (2006) Effect of semi-solid processing on solidification microstructure and mechanical properties of gray cast iron. Referencesj409 Materials Science and Engineering A, 417, 166–173. 47 Aguilar, J., Fehlbier, M., Grimmig, T., Bramann, H., Afrath, C. and B€uhrig- Polaczek, A. (2004) Semi-solid processing of metal alloys. Steel Research International, 75 (8/9), 492–505. 48 UBE Industries (1996) European Patent EP 0 745 694 A1. 49 Yurko, J.A., Martinez, R.A. and Flemings, M.C. (2002) Development of the semi-solid rheocasting (SSR) process, Proceedings of the 7th International Conference on Semisolid Processing of Alloys and Composites (S2P), p. 659. 50 Pan, Q.Y., Findon, M. and Apelian, D. (2004) The continuous rheoconversion process (CRP): a novel SSM approach, Proceedings of the 8th International Conference on Semi-solid Processing of Alloys and Composites (S2P), session 2. 51 Kaufmann, H., Potzinger, R. and Uggowitzer, P.J. (2001) The relationship between processing and properties of new rheocast AZ91 and AZ71 magnesium parts. Light Metal Age, 56. 52 Jorstad, J., Thiemann, M. and Rogner, R. (2005) SLCÔ- Subliquidus Casting: an economical route to rheocasting Proceedings of the 8th Esaform Conference on Material Forming, p. 1116. 53 Kopp, R., Hirt, G., Shimahara, H., Seidl, I., K€uthe, F., Abel, D. and Sch€onbohm, A. (2005) Semi-solid forging of 100Cr6 and X210CrW12 steel, 55th CIRP General Assembly, Antalya, Turkey, 21–27 August 2005, STC F, 54/1/2005, p. 257. 54 Behrens, B.A., Haller, B. and Fischer, D. (2004) Thixoforming of steel using ceramic tool materials. Steel Research International, 75 (8/9), 561.
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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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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
Page 382 and 383: Figure 9.44 Microstructure of Zr/Sc
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Page 388 and 389: D grain diameter of a circle DGM De
Page 390 and 391: 27 Doppelbauer, M. (2003) Wirtschaf
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Page 394 and 395: 1970s [7]. Also, the quality of the
Page 396 and 397: 10.3 Heating and Forming Operations
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Page 402 and 403: material properties have to be cons
Page 404 and 405: 10.3 Heating and Forming Operations
Page 406 and 407: Figure 10.9 Experimental results, d
Page 408 and 409: Figure 10.12 Segregation in compone
Page 410 and 411: 10.3.4 Thixoforging of Steel In thi
Page 412 and 413: 10.3.5 Thixojoining of Steel In the
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Page 422 and 423: The investigations show that the rh
Page 424 and 425: Figure 10.31 Scheme of the heat tra
Page 426 and 427: Table 10.2 Definition of boundary c
Page 428 and 429: Figure 10.35 Experimental and simul
Page 430 and 431: References 1 Koesling, D., Tinius,
Page 434 and 435: 11 Thixoextrusion Frederik Knauf, R
Page 436 and 437: 11.2 State of the Artj413 directly
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Page 440 and 441: Figure 11.2 Schematic diagram of th
Page 442 and 443: Figure 11.5 Shamrock-like thixoextr
Page 444 and 445: Table 11.2 Comparison of required f
Page 446 and 447: Carbon content (%) 4,0 3,5 3,0 2,5
Page 448 and 449: Table 11.5 Tool characteristics of
Page 450 and 451: Extrusion load (kN) 50 40 30 20 10
Page 452 and 453: Opening mechanism Length = 1750 mm
Page 454 and 455: Figure 11.19 Shell formed while ext
Page 456 and 457: Temperature (°C) 1260 1240 1220 12
Page 458 and 459: Figure 11.26 Microstructure of sele
Page 460 and 461: Figure 11.28 Model for extrusion pr
Page 462 and 463: solidification could be realized by
Page 464 and 465: shell. Therefore, for the non-isoth
Page 466 and 467: Index a ab initio calculations 148
Page 468 and 469: constant temperature process (CTP)
Page 470 and 471: h hardness/coating thickness 256 ha
Page 472 and 473: melting alloys 179 - aluminium 179
Page 474 and 475: adiation trials 400 ram speed 232 r
Page 476 and 477: - X210CrW12 21, 63 Stefan-Boltzmann
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