Thixoforming : Semi-solid Metal Processing

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shell. Therefore, for the non-isothermal extrusion process, prevention of such sticking shells and ensuring complete solidification are the main challenges. Solving these problems could eventually be achieved by a combination of both concepts. A first ceramic zone where the material is formed under (nearly) isothermal conditions, followed by a long cooling channel with an integrated active cooling system, could ensure that all requirements are met for successful semi-solid extrusion. An additional mechanism to carry the bar weight is also an option. Abbreviations and Units HPDC high pressure die casting e.g. for example A0/A1 extrusion ratio A0, A1 cross section Ts solidus temperature TB billet temperature T temperature F press force v velocity fL fraction liquid T0 initial temperature TB,0 initial billet temperature TD,0 initial die temperature TW,0 initial water cooling temperature Ichannel extrusion channel length vbar bar extrusion velocity vpress press velocity tsolidification time for solidification Ø diameter h height hD die height a angel alpha TC Thermocouple PVD Physical vapour deposition mm/s velocity s 1 strain rate mm length mm2 cross section angle C Celsius temperature K Kelvin temperature MPa pressure kN/MN force N/mm 2 pressure 11.6 Conclusionj441
442j 11 Thixoextrusion GPa pressure W/m 2 K heat transfer coefficient Hz frequency W/kW power % percent References 1 Lange, K. (1985) Handbook of Metal Forming, Society of Manufacturing Engineers, Dearborn, MI. 2 Kiuchi, M., Sugiyama, S. and Arai, K. (1979) Study of metal forming in the mashy-state; 2nd Report. Extrusion of tube, bar and wire of alloys in mashy-state, Proceedings of the 20th International Machine Tool Design Conference. 3 Kiuchi, M. and Sugiyama, S. (1994) Proceedings of the 3rd International Conference on Semi-solid Processing of Alloys and Composites, pp. 245–257. 4 M€oller, T. (2004) Verfahrensentwicklung und Ermittlung des thermischen Prozessfensters beim Thixostrangpressen, Dissertation, RWTH Aachen. 5 Miwa, K. and Kawamura, S. (2000) Proceedings of the 6th International Conference on Semi-solid Processing of Alloys and Composites, pp. 279–281. 6 Rouff, C., Bigot, R., Favier, V. and Robelet, M. (2002) Proceedings of the 7th International Conference on Semi-solid Processing of Alloys and Composites, A63, pp. 355–360. 7 Abdelfattah, S., Robelet, M., Rassili, A. and Bobadilla, M. (2000) Proceedings of the 6th International Conference on Semi-solid Processing of Alloys and Composites, pp. 283–288. 8 Sugiyama, S., Li, J.Y. and Yanagimoto, J. (2004) Proceedings of the 8th International Conference on Semi-solid Processing of Alloys and Composites, TMS Publications, Warrendale, PA. 9 Knauf, F., Baadjou, R. and Hirt, G. (2008) Proceedings of the 10th International Conference on Semi-solid Processing of Alloys and Composites. 10 M€unstermann, S., Telle, R., Knauf, F. and Hirt, G. (2008) Proceedings of the 10th International Conference on Semi-solid Processing of Alloys and Composites. 11 P€uttgen, J.T.W., Hallstedt, B., Bleck, W. and Uggowitzer, P.J. (2007) Acta Materialia, 55, 1033–1042. 12 Knauf, F., Hirt, G., Immich, P. and Bobzin, K. (2007) Influence of tool geometry, tool coating and process parameters in thixoextrusion of steel, Proceedings of ESAFORM. 13 Shimahara, H. (2007) Personal communication. 14 Thome, R. (1998) Einfluss der chemischen Zusammensetzung und der Abk€uhlbedingungen auf die Rissanf€alligkeit von Werkzeugst€ahlen beim Stranggiessen und bei der Warmumformung, Dissertation, RWTH Aachen. 15 Uhlenhaut, D.I., Kradolfer, J., P€uttgen, W., L€offler, J.F. and Uggowitzer, P.J. (2006) Acta Materialia 54 (10), 2727–2734. 16 Shimahara, H., Baadjou, R. and Hirt, G. (2006) Solid State Phenomena, 116–117, 189–192.
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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
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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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Page 473 and 474: 450j Index oxygen-sensitive element
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Thixoforming : Semi-solid Metal Processing

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