Thixoforming : Semi-solid Metal Processing

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Index a ab initio calculations 148 additive elements 293 adhesive/cohesive failure 280 aerospace industry 118 agglomeration process 189, 226 – deagglomeration 225 algebraic equations 197 alkali metal contaminants 120 – effect 120 – schematic presentation 120 Al-Li alloys 2, 6, 10, 19, 50, 52, 53, 116, 119, 121, 126, 139, 184, 185, 192, 311, 316, 358, 383, 413 – acceptance 117 – AlMg5SiMn 2 – extrusion 383 – fundamentals 116 – industrial thixocasting 2 – mechanical properties 316 – mix crystal 137 – recycling 139 – rheocasting 311 – semi-<strong>solid</strong> forming 3 Al-Li-Mg alloys 117, 118, 124, 127, 131, 137, 371 – design 105 – diagrammatic presentation 133 – grain refinement 124 – principle component 133 – selection 118 – thixocasting/thixomoulding 371 Al-Li-Mg system 122, 128 – alloy compositions 128 Al-Li residues 139, 142 – closed-loop recycling 142 Al-Li thixoalloys 132, 322 – adaptation 122 – flow diagram 122 – matrix 117 – rheocasting 134 – systems 127 – thixocasting 132, 314 alloy systems 44, 61, 148 – adaptation procedure 110 – composition 110 – elements 50, 61, 112, 290, 349, 423 – modification 54 alloying elements, see carbon Al2O3 insulating mats 352 Al 2O 3/ZrO 2-based ceramics 282 Al-Si-based alloys 317 alumina films 273–277, 279–281 – bright-field TEM images 276, 277 – coatings 269 – crystallographic structure 274 – matrix 277 – optical micrograph 279 – phase-formation diagram 273 – plates 297 – raw material 126 – SEM images 275 – tribiological tests 280 aluminium 383 – alloy A356 48, 169, 210 – billets 9 – dendrites 107 – dendrites agglomerate 113 – grain nucleation parameters 210 – phase 115 – production 9 – rheometer 186 – thixoforging/thixo lateral extrusion 383 aluminium titanate (Al2TiO5) 282 analogous quench tests 124 j443
444j Index arbitrary volume element 222 argon atmosphere 290 ASTM grain size 83 austenite particles 71 – carbon 89 – chromium 89 – grains 77 – liquid phase boundary 75 – martensitic matrix 96, 193 – matrix 193 – protuberances 81 – stabilizing elements 89 – transforms 87 automated thixo cell 391 automatic robot 344 automotive applications 1 – brake cylinders 1 – chassis components 1 – rims 1 automotive/aerospace industries 311 automotive industry 315 axial/radial temperature measurements 320 axisymmetric geometry 387 b ball-on-disk configuration 271 billet 115 – grain structure 115 – material 431, 435 – reheating 10 – schematic drawing 322 – stands 12 – temperature 412 – tray 320, 322 bimodal distribution 225 binary alloy 51 – schematic phase diagram 51 binary/ternary systems 130 bipolar DC PECVD method 269 body-centred components 76 boron nitride (BN)-based side dams 282 bright-field TEM images 276 brittle scale layer 290 BSE micrograph 38 bulk ceramic forming tools 281 c Calphad method 148 Calphad software 149 capillary experiments 192, 193 capillary Rheometer 171, 177–179, 189, 191 – horizontal 179 – tool 190 – vertical 178 – viscometer 178 carbide bands 63 – accumulations 65 – content 71 – metallographic determination 71 carbon 57 – content changes 74 carbon/chromium contents 90 carbon pins 181 – thermodynamic calculations 90 Carousel-type machine 11, 12 – induction coils 11 – schematic diagram 12 cartridge system 323 casting process 40 CCT diagram 88, 91, 92 ceramic machining technologies 296 ceramic materials 245, 281 – mould 347 – plates 331 – sintering additives 293 – spindle 176 – tools 283, 298 chemical vapour deposition (CVD) 248, 250 – process 272 chlorine bubbles 270 chromium carbides 96, 193 chromium/carbon-rich steel 64 – 100Cr6 64 chromium templates 269 Clausius–Clapeyron equation 127 closed-loop control 377 – scheme 380 CNC-controlled green machining 296 coarsened silicon particles 10 coated extrusion segment 268 – SEM/EDS analysis 268 coated tool 268 – SEM/EDS analysis 268 coating systems 248 Cobapress method 317 coefficient of thermal expansion (CTE) values 247 coil geometry 375 coil heating system 13 – diagramatic presentation 13 components geometries 385 – segregation 385 compression test 182, 193 – experimental setup 182 computational fluid dynamics (CFD) 197 – program 200 – software FLUENT 6.3 208
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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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einforcing element. The possibiliti
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Page 471 and 472: 448j Index - importance 273 ion flu
Page 473 and 474: 450j Index oxygen-sensitive element
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Thixoforming : Semi-solid Metal Processing

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