List of Abbreviations DC direct chill MHD magnetohydrodynamic MMC metal matrix composite SIMA strain induced melt activated SSM semi-<strong>solid</strong> metal SSP single slug production CRP continuous rheoconversion process LSPSF low superheat pouring with a shear field References 1 Spencer, B., Mehrabian, R. and Flemings, M.C. (1972) <strong>Metal</strong>lurgical Transactions, 3, 1925. 2 Flemings, M.C., Riek, R.G. and Young, K.P. (1976) Materials Science and Engineering, 25, 103–117. 3 Flemings, M.C. and Young, K.P. (1978) Yearbook of Science and Technology, McGraw-Hill, New York, pp. 49–58. 4 Midson, S.P., Nicholas, N.H., Nichting, R.A. and Young, K.P. (1992) Proceedings of the 2nd S2P Conference, Cambridge, USA, pp. 140. 5 Kapranos, P., Kirkwood, D.H. and Sellars, C.M. (1993) Journal of Engineering Manufacture, B1a, 207 (4), 1. 6 Kiuchi, M., Sugiyama, S. and Arai, M. (1996) Journal of the Japan Society for Technology of Plasticity, 37 (430), 1219–1224. 7 P€uttgen, W., Bleck, W., Seidl, I., Kopp, R. and Bertrand, C. (2005) Advanced Engineering Materials, 7 (8), 726. 8 P€uttgen, W., Pant, M., Bleck, W., Seidl, I., Rabitsch, R. and Testani, C. (2006) Steel Research International, 77 (5), 342–348. 9 Omar, M.Z., Palmiere, E.J., Howe, A.A., Atkinson, H.V. and Kapranos, P. (2005) Materials Science and Engineering A, 395, 53–61. 10 Behrens, B.A., Haller, B. and Fischer, D. (2004) Steel Research International, 75 (8/9), 561. Referencesj25 11 Rassili, A., Robelet, M. and Fischer, D. (2006) Proceedings of the 9th ESAFORM Conference, Glasgow, pp. 819–822. 12 Tsuchiya, M., Ueno, H. and Takagi, I. (2003) JSAE Review, 24, 205–214. 13 K€uthe, F., Sch€onbohm, A., Abel, D. and Kopp, R. (2004) Steel Research International, 75 (8/9), 601–606. 14 Hirt, G., Shimahara, H., Seidl, I., K€uthe, F., Abel, D. and Sch€onbohm, A. (2005) CIRP, 54/1, 257–260. 15 Flemings, M.C. (1991) <strong>Metal</strong>lurgical Transactions A, 22 (5), 957. 16 Atkinson, H.V. (2005) Modelling the semi<strong>solid</strong> processing of metallic alloys. Progress in Materials Science, 50, 341–412. 17 Hirt, G., Bleck, W., B€uhrig-Polaczek, A., Shimahara, H., P€uttgen, W. and Afrath, C. (2006) Proceedings of the 9th S2P Conference, Korea. 18 Kenney, M.P., Courtois, J.A., Evans, R.D., Farrior, G.M., Kyonka, C.P., Koch, A.A. and Young, K.P. (1988) <strong>Metal</strong>s Handbook, Vol. 15, 9th edn, ASM International, <strong>Metal</strong>s Park, OH, pp. 327–338. 19 Fan, Z. (2002) International Materials Reviews, 47, 49–85. 20 de Figueredo, A. (ed.) (2001) Science and Technology of <strong>Semi</strong>-<strong>solid</strong> <strong>Metal</strong> <strong>Processing</strong>, North American Die Casting Association, Rosemont, IL.
26j 1 <strong>Semi</strong>-<strong>solid</strong> Forming of Aluminium and Steel – Introduction and Overview 21 Midson, S.P. (1996) Proceedings of the 4th S2P Conference, England. 22 Young, K.P., Kyonka, C.P. and Courtois, J.A. (1982) Fine grained metal composition, US Patent 4,415,374, 30 March. 23 Young, K.P. (1987) US Patent 4,687,042. 24 Kenney, M.P., Young, K.P. and Koch, A.A. (1984) US Patent 4,473,107. 25 Moschini, R. (1992) Manufacture of Automotive Components by <strong>Semi</strong>-Liquid Forming Process. Proceedings of the 2nd S2P Conference, USA. 26 Gabatuler, J.-P. (1992) Proceedings of the 2nd S2P Conference, USA. 27 Wan, G., Witulski, T. and Hirt, G. (1994) <strong>Thixoforming</strong> of aluminium alloys using modified chemical grain refinement for billet production. La <strong>Metal</strong>lurgia Italiana, 86 (1), 29–36. 28 Kirkwood, D.H., Sellars, C.M. and Elias Boyed, L.G. (1992) Thixotropic materials. European Patent 0305375, 28 October. 29 Young, K.P. and Fitze, R. (1994) Proceedings of the 3rd S2P Conference, Japan. 30 Behrens, B.-A., Fischer, D., Haller, B., Rassili, A., Klemm, H., Fl€uss, A., Walkin, B., Karlsson, M., Robelet, M. and Cucatto, A. (2004) Proceedings of the 8th S2P Conference, Cyprus, Session 1. 31 Hirt,G.,Cremer,R.andSommer,K. (1997) Sensor controlled induction heating for semi <strong>solid</strong> forming of aluminium alloys. Proceedings of Congres International de l Induction dans les Procedes Industriels, Paris, 26–29 May, Vol. 1, pp. 489ff. 32 Hirt, G., Cremer, R., Sommer, K. and Witulski, T. (1997) Advances in thixoforming – plant technology, component manufacturing and simulation. Proceedings of Nadca s 19th International Die Casting Congress and Exposition, Minneapolis, MN, 3–6 November, pp. 377–382. 33 Cremer, R., Winkelmann, A. and Hirt, G. (1996) Sensor controlled induction heating of aluminium alloys for semi <strong>solid</strong> forming, Proceedings of the 4th S2P Conference, England. 34 Gr€af, T., J€urgens, R. and Gies, J. (2000) Controlled inductive heating for thixotropic materials into the semi-<strong>solid</strong> state. Proceedings of the 6th S2P Conference, Italy. 35 Hall, K., Kaufmann, H. and Mundl, A. (2000) Proceedings of the 6th S2P Conference, Italy (eds G.L. Chiarmetta and M. Rosso). 36 UBE Industries (1996) Method and apparatus of shaping semi<strong>solid</strong> metals. European Patent 0745694. 37 Haga, T., Kapranos, P., Kirkwood, D.H. and Atkinson, H.V. (2002) Proceedings of the 7th S2P Conference, Japan. 38 M€uller-Sp€ath, H., Achten, M. and Sahm, P.R. (1996) Proceedings of the 4th S2P Conference, England. 39 Pan, Q., Wiesner, S. and Apelian, D. (2006) Proceedings of the 9th S2P Conference, Korea. 40 Langlias, J. and Lemieux, A. (2006) Proceedings of the 9th S2P Conference, Korea. 41 Guo, H. and Yang, X. (2006) Proceedings of the 9th S2P Conference, Korea. 42 Wannaish, J., Martinez, R.A. and Flemings, M.C. (2006) Proceedings of the 9th S2P Conference, Korea. 43 Xing, S., Zhang, L., Zhang, P., Du, Y., Yao, J., Wu, C., Wang, J., Zeng, D. and Li, W. (2002) Proceedings of the 7th S2P Conference, Japan. 44 Hirt, G., Cremer, R., Tinius, H.-C. and Witulski, T. (1998) Lightweight near net shape components produced by thixoforming, Materials and Design, 18 (4/6), 315–321. 45 Kapranos, P. and Atkinson, H.V. (2002) Proceedings of the 7th S2P Conference, Japan. 46 Witulski, T., Morjan, U., Niedick, I. and Hirt, G. (1998) Proceedings of the 5th S2P Conference, USA. 47 Dualcan Composites – Mechanical and Physical Property Data, Duralcan Bulletin, February (1990).
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Temperature (ºC) 1550 1500 1450 14
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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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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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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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10.3.5 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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Figure 10.31 Scheme of the heat tra
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Figure 10.35 Experimental and simul
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References 1 Koesling, D., Tinius,
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steel billets into the semi-solid s
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