Thixoforming : Semi-solid Metal Processing

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melting alloys 179 – aluminium 179 – magnesium 179 – modular design 179 melting curve 157 melting energy 380, 381 melting point alloys 3 MeSES code 208, 215 metal alloys 411 metal flow 314 metal matrix composites (MMCs) 20, 317 metal <strong>solid</strong>ification process 52 metal velocity 341 – simulation 341 metallic alloys 169, 247 – alloys 247 – steel 247 metallic melt 4 metallic precipitations 290 metallic suspensions 46, 169–171, 175, 183, 186 – rheological behaviour 175 – structural changes 46 – yield stress 186 metallic tool 292 – frames 296 metallographic image 59, 84 metallographic tests 115 metallurgical raw material production 135 MHD agitation 126 MHD grain structures 114 MICRESS simulation 353 micro-macro model 229 micromechanics/homogenization techniques 221, 222 microprobe examination 72, 79 microstructure analysis 87, 435 microstructure parameter determination 81 – assessment 81 model tests 290 molybdenum-based alloy (TZM) 248, 332, 400 molybdenum disilicide 296 momentum conservation equations 198 monolithic steel 181 mould filling behaviour 327 multi-stage forging process 3 multicomponent pins 181 multilayer system W-ZrO2 261 – deposition parameters 261 multiphase areas 43 multisectional tool 337 n near-isothermal steel thixoextrusion experiments 299 needle-shaped pearlite 94 – interference-contrast image 94 Newtonian flow behaviour 184 Newtonian fluid 45, 172, 226 NIF values 279 nitride/boride-based coatings 248 nitrogen gas 289 non-interacting particles 173 non-isothermal compression tests 235 – concept 416 – filling experiment 207 – non-isothermal effects 169 – non-steady-state behaviour 234 – schematic diagram 417 – simulated load-displacement curves 235 – <strong>solid</strong> fraction distribution 169 – thixoextrusion experiments 428 – tool 416 non-metallic contamination 130 non-oxide ceramics 282 non-porous body 277 – elastic modulus 277 non-returnable container 356 nucleation/crystal growth process 52 nucleation parameters 210 numerical models 197 numerical solution techniques 199 – discretization methods 199 o oil pump 319 one-dimensional cooling simulation 432 – schematic diagram 432 one-phase models 6 open-loop control schemes 378 oscillating circuit parameters 320 oscillation experiments 188 Ostwald ripening 58, 171, 188, 350 oxide-free material 326 oxide-resistant skin 326 oxide ceramics 294 – alumina 294 – coating materials 249 – zirconium oxide 294 oxide restrainer 334 – thermograph 334 oxide systems 148 oxygen flow rate 262 – effect 262 oxygen partial pressure 263, 294 Indexj449
450j Index oxygen-sensitive elements 358 – magnesium/lithium impede 358 p parameter-independent fine globular microstructure 435 parameter determination/adjustment 204 – procedure 204 partial differential equation 375 partial liquid bodies 45 partial liquid materials 67 – holding experiments 67 partial liquid metallic suspensions 47 – rheological characteristics 47 partial liquid metals 59 partial liquid state 51, 56, 67, 86 – microstructure 51 particle-reinforced aluminium alloy 413 passive stirring 9 peak voltage 273 – parameters 273 pearlite nose 92 performance-related tests 279–281 – adhesion 281 – high-temperature tribiological 281 – thermal shock evaluations 281 phase boundary surface 77 phase diagram 147 phase fractions 55 physical vapour deposition (PVD) 246 – coating 251, 267 – compression plates 266 – hot working steel 267, 301 – machine 260 – metallic mould 251 – method 249 – PECVD coating technologies 249 – process technology 301 – technology 254 PID controller 381, 394 piezoelectric pressure sensors 178 pilot experiments 337 planetary motion 263 plasma-assisted CVD process 250 plasma-based deposition technique 250 plasma-enhanced chemical vapour deposition (PECVD) 246 – coating 251 – collisions 251 – deposition chamber 270 – process 272 – schematic presentation 251, 270 – system 270 – technology 301 plastic deformation 10, 253 pneumatic cylinder 391 porous structure 276 power density (PD) 272 – influence 272 power generators 12 power input 12 power-time curve 13, 14 precursor material 349 preheated tool 405 pressure-tight components 19 – fuel rails 19 pressure-time curves 181 primary/secondary austenite 77 process-adapted shot chamber system 323 process-adapted shot sleeve system 325 process parameters 169, 298, 336, 430, 434 – holding time 169 – piston velocity 169 – pressure 169 – variation 430, 433 process-relevant material data 63 – heat transmission coefficients 63 process simulation 210 process-specific disadvantage 316 process temperature 349 process window 411 – diagram 412 processing stages 370 – forging 370 – roll forging 370 – upsetting 370 programmable logic controller (PLC) 392 proportional-integral-derivative (PID) controller 380 prototyping steel tools 335 pseudo-binary phase diagram 87 pump housings 387 pyramid diamond hardness 360 q quasi-ledeburitic carbides 65 – development 65 quenching experiments 71, 80, 81, 83, 85, 188 – microstructures 85 – temperature-time curve 85 – thermodynamic calculations 81 quotient pyrometer 381 r radial gradients 11 radiation experiment 399, 400 – scheme 400 radiation pyrometer 380
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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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Figure 10.21 Experimental results w
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Figure 10.24 Design and working pri
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Page 469 and 470: 446j Index equilibrium tests 141 eq
Page 471: 448j Index - importance 273 ion flu
Page 475 and 476: 452j Index - thixoforming 241 semi-
Page 477: 454j Index - high pressure 131 - sc
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Thixoforming : Semi-solid Metal Processing

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