Thixoforming : Semi-solid Metal Processing

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constant temperature process (CTP) 342, 355 constitutive equation 173, 174 continuous-cast/extruded billets 105 continuous-pressed profiles 116 continuous rheoconversion process (CRP) 15 converter system voltage 321, 373 cooling channel 208 – device 352 – process 211, 342, 344, 345, 347, 355 – simulation 208, 211 – variable parameters 345 cooling/heating experiments 46 cooling slope method 15 cooling tube 434 copper-based material 333 copper-beryllium alloy 389, 390, 432 copper bronze CDA905 317 corrosion test 249, 287 – experiments 286 – schematic diagram 287 corrosive effects 293 cost-effective casting technique 117 cost-effective fully liquid casting process 1 Couette Rheometers 175 – high-temperature 175 CPR reactor 15 Creep experiments 186 – tests 187 CSM Instrument tribometer 271 CuCrZr based alloy segment 248 Curie temperature 321 d Darcy s law 199 dark matrix 71 DC sputtering technology 255 deagglomeration process 225 deformation mechanisms 232 dendritic primary material 54 – microstructure 52, 58, 347, 353 – reheating 58 – solid-phase particles 43 dense/porous ceramic 295 deposited coatings 248, 259 – X-ray diffraction pattern 259 depositing technology 248 deposition parameters 252, 260, 265 – deposition pressure 260 – development 254 – oxygen flow rate 260 – process 263 die-casting machine 319 die-casting tool 178, 324 differential/integro-differential equations 197 differential scanning calorimetry (DSC) 55 differential thermal analysis (DTA) 55, 114, 147 – curves 128 – high-pressure 128 – measurements 82 – signal 153 – system 128 – testing 127, 132, 138 diffusion-controlled process (DICTRA) 67, 150 – curve 160 – diffusion simulations 150 – simulation 151, 152, 158, 159 diffusion process 31, 47, 67 dilatometer experiments 92 – metallographic images 92 direct chill casting 9 – mould 9 direct metal laser sintering (DMLS) 335 discretization methods 199 – numerical solution techniques 199 discretized/discretization equation 200 diving knife 339 2D-MICRESS simulation 351 double scale transition 228 – schematic representation 228 draft angles 370 drop forging process 369 dynamic mechanical component 86 dynamic yield stress 186 e EBSD measurements 76, 77, 80 EDS graph 267 elastic modulus 277 – values 277 electric heating cartridges 179, 324 electric parameters 13 electromagnetic/active mechanical stirring 9 electromagnetic qualities 321 electromagnetic stirring methods 1 – stirred material 57 electronic products 8 – laptop housings 8 element-distribution images 73 Elotherm reheating unit 320 energy-dispersive spectroscopy (EDS) 253 enthalpy/heat capacity 155 – bar graph 155 equilibrium flow curve, see Herschel–Bulkley Law Indexj445
446j Index equilibrium tests 141 equilibrium viscosity curves 184 equivalent stress 174 etching process 263 eutectic structure 113 – involvement 113 extrusion channel 415, 432 extrusion experiments 414 – diameter 414 – forces 420 – forming process 411 – load/displacement curves 420 extrusion process 369, 415, 416, 437 – model 437 – simulation 437, 439 – temperature development 437 extrusion tool 428, 429 – schematic diagram 429 f FACTSAGE program 139 fast-diffusing element 151 Fe-Cr-W-C system 62, 66 – pseudo-binary phase diagram 62, 66 feed-forward control 394 feedstock billets 20 feedstock magazine 391, 393 feedstock material 31, 35, 348 – extruded/rolled 35 – hot deformed/homogenized 35 ferritic/homogenization phase 321 ferritic/martensitic/austenitic state 156 ferrous oxides 290 filling/cutting sequence 396 – scheme 396 filling process 205 – two-phase simulation 205 fine-grained globular microstructure 7, 9 fine particles 339 finite difference method (FDM) 199, 377 – inductive heating 377 finite element-method (FEM) 175, 200, 221 – analysis 300 – concepts 222 – simulations 195, 221, 428 finite volume method 199 firebricks 296 flat bar tension specimens 360 flatness-based control 378, 381 – introduction 378 flatness-based control 382 Flir ThermaCam P640 thermographic camera 348 flow behaviour 172 – mathematical modelling 172 flow length capabilities 328 – determination 328 flow pressure 180 fluid mechanics 172 – approach 172 – suspension 44 fluid/solid phase distribution 131 – Al-Li phase diagram 131 Fondarex system 323 forging process 394 – control 394 – micrographs positions 397 – schematic view 397 – steps 397 fourfold plate sample 331 g gas bubbles technique 16 gas inclusion 369 gas pressure sintered silicon nitride (GPSN) 287 gaseous nitrogen 285 gating system 325 Gaussian curve 210 geometric probability computation 54 Gibbs energy 148 glassy grain boundary phase 287 globular-equiaxed transition 350 globular grains 346 globular microstructure 342, 348, 349, 356 globular solid particles 4, 5, 7, 43, 172, 223 globulitic metal suspensions 45 globulitic microstructure 123 – formation 123 globulitic primary phase 422 globulitic solid phase 108 grain boundary areas 80 – segregation 80 grain-density model 209, 214 grain nucleation model 209 – determination 209 – parameters 209 grain refinement 106, 108, 111 – element 114 – material 114, 115 – modifying agents 111 grain size distribution 56 – influence 56 – rheological properties 56 granular crystals nucleate 15 grey-value thresholds 70 – structural evaluation 70
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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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Figure 10.20 The robot controller a
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Page 432: steel billets into the semi-solid s
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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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