Thixoforming : Semi-solid Metal Processing

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– X210CrW12 21, 63 Stefan–Boltzmann constant 376 step-shooting experiments 325, 338 stirring modes 9 – mechanical stirring 9 – passive stirring 9 strategy/tools and process parameters 418 stress induced and melt activated (SIMA) process 105 stress/strain rate tensors 227 strontium-refined/titanium grain-refined alloy 343 substrate current/voltage 271 – time-dependent evolution 271 surface oxides 17 suspension rheology, see oscillation experiments Swiss Federal Institute of Technology 360 t T-shaped die-filling experiment 203 temperature distribution 402–404 – heat conductivity 403 temperature interval size 48 temperature sensitivity 48 – measurement module 177 terminal freezing range (TFR) 32, 38 testing tool plate 265 tetragonal martensite 63 tetragonal phase 261 textile industry 294 thermal boundary 244 thermal gradients 296 thermal insulation materials 295 – thermal conductivity 295 thermal process 242, 283 thermal shock 244, 285, 298 – resistance 244, 282, 283, 288, 294 – sensitive materials 294 thermal spray coatings 245 Thermo–Calc software 148 thermochemical calculations 121, 140 – experimental validation 140 thermochemical metal-salt equilibrium 139 thermochemical modelling 121 thermochemical simulation methods 147 – equilibrium calculations 149 – Thermo-Calc software 148 thermodynamic calculations 55, 67, 69, 79, 82, 89 thermodynamic data 55, 148 – database 156 – usage 55 thermodynamic diffusion calculations 76 thermodynamic equilibrium calculations 76 thermomechanical stress 300 thermomechanical treatment 10 thermophysical/thermodynamic data 401 thin-film analysis equipment 258 thin-film deposition techniques 249 thin-film PVD/PECVD coating 247 thin-film techniques 256 – nanoin-dentation 256 – XRD 256 thin-walled components 387 thixo-cast step samples 116 – grain structure 116 thixo/rheoforging process 371 thixo-steel component 339 thixocast A356 357 – elongation 357 – model components 317 thixocasting process 312, 317–319, 325, 330, 332, 337 – layout 312 – simulation 325 thixocasting route 311 – aspects 311 thixocasting step samples 133 – aluminium-lithium alloys 133 thixocasting/thixoforging steels 415 thixoextrusion experiments 430, 431, 439 thixoextrusion process 436 – numerical simulation 436 thixoforging components 383, 401 – simulation 401 thixoforging experiments 392 thixoforging operation 373 thixoforging tools 296 thixoforging/thixo lateral extrusion 18, 369 – process 389 – schematic view 369, 370 thixoformed components 196 thixoformed specimens 100 thixoforming 44 – background 44 thixoforming experiments 293, 294, 298 thixoforming feedstock formation 208 – simulation 208 thixoforming material(s) 108, 109, 111, 387 – assessment 111 – parameter 109 thixoforming moulds 251, 269 thixoforming process 14, 17, 52, 100, 105, 106, 131, 196, 241, 255, 265, 300, 391, 392, 399, 405 – alloy decomposition 100 Indexj453
454j Index – high pressure 131 – schematic presentation 106 – simulation 399 – tool concepts 241 thixojoining components 389 thixotropic effects 172 thixotropic fluids 172 thixotropic material 111 thixotropic metal suspensions 45 – rheological behaviour 45 thixotropic model 198 Ti/Zr grain-refined alloys 126 – AlLi4Cu4 126 – AlLi4Mg8 126 TiAlZrN interlayer 263 time-dependent flow 169 time-dependent thixotropic behaviour 5 time-dependent viscosity 6, 179 time-temperature curve 190 tin-lead alloy 170, 186 TiN particles 84, 86 titanium-doped 100Cr 6 specimens 84 – element distribution images 84 titanium nitride 82, 83 – effect 82 – solubility limit 83 titanium-zirconium-molybdenum (TZM) 330, 403 – cores 341 – mould 251 – segments 253 – substrate 253 – tool 401 tool design/construction 296 tool geometry 137, 418 tool materials 24 – rating matrix 24 tool steel X210CrW12 150 – calculations 150 – schematic presentation 150 tool surfaces 333 – thermography 333 tool systems 247 trajectory planning tasks 378 transformation kinetics 96 transmission electron microscopy (TEM) 275 transport equations 209 tribochemical attack 283 triboindenter apparatus 271 tube-like oxide layer 355 twin-screw rheomoulding 107 two-phase network 87 two-phase system 223 u UDS200 Couette rheometer 186 upscaled extrusion tests 425 v vacuum arc-based deposition 249 vacuum-formed refractory fibre 296, 322 validation experiments 213, 353 vertical capillary viscometer 179 Vexocast process 107 vigorous agitation 5 – schematic illustration 5 Viscometer 179 viscoplastic constitutive equations 174 viscoplastic material 226 volatile precursors 250 volume of fluid (VOF) model 200 – technique 200 volume power density 374 w warm-working steel 98 water-cooled rack 179 water-cooled sample 354 welded fuel tanks 119 welding, see heat treatment Widmanstatten carbides 94 x X-ray diffraction (XRD) 255 – analysis 290 – measurements 255 – patterns 258 X-ray mapping 38 X-ray micro-tomography 56 X-rayed thixocast steel 336 y yield stress 187 – schematic diagram 187 Young s modulus 251, 258, 263, 265, 423 z zirconium metal oxide 260, 294, 330 ZrO 2-based coatings 260 ZrO2-coated plates 267 ZrO2 hysteresis 264 Zr/Sc-microalloyed AA1420 359 – microstructure 359
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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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Figure 10.31 Scheme of the heat tra
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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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