Thixoforming : Semi-solid Metal Processing

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adiation trials 400 ram speed 232 raw material 114 – characteristics 114 raw material development programme 125 – assessment 125 reactive magnetron sputtering 251 refractory reaction 293 reheating/semi-solid casting 21 reheating time 111, 112 remnant metal 346 resilient components 315 resonant circuit 373 restraining system 326 rheo-cast tie rods 363 – mechanical properties 363 rheocasting process 1, 14, 107, 312, 395 – scheme 395 – route 15 rheo-container process (RCP) 135, 313, 355 – implementation 135 rheo-process 52, 364 rheoforming plants 316 rheoforming process 396 rheological experiments 190, 203 Rheometer 9, 175 – tests 9 robot controller 393 robust process 10 Rockwell hardness (HRC) 339 roller-bearing steel 100Cr6 64 – components 64 rotating rod sticks 176 – advantages/disadvantages 175 rotational Rheometer 183 RVE boundaries 223 s salt systems 148 scanning electron microscopy (SEM) 253 – analysis 423 – EDS substantiates 299 – images 95 Scheil–Gulliver calculations 149, 150 scrap metal 16 scratch test measurements 279 secondary austenite 71 secondary dendrite arm 150 secondary electrons 273 SEED process 14, 16 SEED technology 16 – heat extraction 16 segmented test 252 – schematic drawing 252 segregation mechanism 385 self-heating alumina 421 self-heating ceramic 295 – schematic tool 295 – thixocasting moulds 297 – thixoextrusion 297 self-heating steel thixoforming 296 – construction 296 self-heating thixocasting mould 297 semi-continuous feeding techniques 296 semi-liquid state 47 semi-solid alloy 203 – processing 18 semi-solid aluminium alloys 189 – billets 16, 18, 320 semi-solid bar extrusion 413, 415 semi-solid bulk material 384 semi-solid casting 19 – capabilities 19 semi-solid extrusion 412 – material 413 – process 412 semi-solid forging process 370 – schematic view 370 semi-solid forging plant 388 semi-solid impact steel extrusion 414 semi-solid material 17, 182, 195, 202, 268, 314, 315, 328, 368, 369, 373, 384, 390, 398 – disadvantage 202 – flow stress 195 – processing 315 – structure 6 – suspensions 191 semi-solid metal (SSM) 1, 2, 7, 221, 251, 299 – advancement 7 – Al-Li components 138 – alloys 169, 313, 371 – metallurgical aspects 31 – microstructure 223, 224 – modification 38 – origins 1 – process 19, 31, 41, 312, 313 – Rheo/Thixo-routes 34 – rheocasting/thixocasting 31 – schematic representation 224 – semi-solid behaviour 223 – slurry-making process 6, 34 – thixotropic behaviour 371 – technology 38, 44, 314 semi-solid process (SSP) 149, 154, 161, 169, 283, 286, 395 – industry-related/target-oriented enhancement 169 – suitability 158, 161 Indexj451
452j Index – thixoforming 241 semi-solid sample 152 semi-solid slug 221 semi-solid slurry 242, 243, 247, 292, 299, 356, 414 semi-solid state 11, 243, 289, 371 – forging 371 semi-solid steel 23, 288, 291, 294, 299 – temperature 415 semi-solid viscosity 227, 230, 231 – evolution 230, 231 sequenced thixoforming methods 411 – thixoforging/thixocasting 411 sequential tool movement 390 Shamrock-like thixoextrusion 419 shear/pressure gradients 6 shear rate jump experiments 183, 184 shear stress 173 shear-thinning thixotropic flow behaviour 196 Sheil equation 234 short-wave thermal image camera 332 Si 3N 4-based ceramics 283 – aluminium titanate (Al2TiO5) 283 silicon carbide 285 silicon nitride 283, 285, 286, 288, 290, 292 – applicability 292 simulated strain rate 233 simulative analysis 399 simultaneous heating process 413 single-phase feedstock material 35 single slug production method (SSP) 15 sintering additives 286 sintering shrinkage 296 slurry production 10 small-scale thixoforging series 288 SMM process routes 8 – diagram 8 software packages 200 – Flow-3D 200 – FLUENT 200 – MAGMASOFT 200 solid bonds 225, 226, 227 – shear rate 226 solid fraction distribution 205 – analysis 205 solid globules 45 – shape 45 solid particles 45, 46, 70, 223, 227, 328 – fluid suspension 46 – morphology 45 solid/liquid phases 54 – concentration 51 – contents 69 – fraction 312 – volume fraction 54 solid-liquid boundary surface 57, 59, 75 solid-liquid fraction 32, 48 solid-liquid interface 153, 342 – interfacial energy 60 solid-liquid phase 138 – boundary 79 solid-liquid suspension 45 solid-phase determination 55 solid-phase fraction 43, 55 solid-phase particles 43, 57, 58 solid-phase protrusions 53 – dissolution 53 solid-phase skeleton fractures 108 solid/semi-solid metals 287 solid-state mechanics 174 – approach 174 solidification process 53, 337 – simulation 53 stable phase diagram 147 state-of-the-art tool solutions 243 steady-state flow curves 183 – thixotropic effects 183 steady-state measurements 193 steady-state temperature 382 steady-state values 177 steel 21, 385 – 100Cr6 77, 159 – alloys 319, 372 – billets 421 – bulk ceramic characteristics 284 – calculations 159 – experimental assembly presentation 176 – extrusion process 411 – heat treatment scheme 63 – material aspects 43 – materials 319 – multitude 319 – phase diagram 159 – profile 242 – rheoforging 395 – Rheometer 175, 176 – schematic temperature evolution 243, 244, 245 – sheet 352 – structural parameters 77 – temperature 361 – thixo lateral extrusion 385 – thixocasting 364 – thixoextrusion 299, 420 – thixoforming 43, 243–245, 267, 268, 282–284, 292–294, 300 – tool 286
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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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The investigations show that the rh
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Page 469 and 470: 446j Index equilibrium tests 141 eq
Page 471 and 472: 448j Index - importance 273 ion flu
Page 473: 450j Index oxygen-sensitive element
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Thixoforming : Semi-solid Metal Processing

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