Papers by Keyword: Semi-Solid Slurry

Abstract: Rheocasting technology has been successfully applied to produce aluminum alloy parts of automobile and communication equipment. However, its application scope is still limited. One reason is that the strength of the applied alloys is limited. In recent years, lots of researchers have tried to use 7075 aluminum alloy in the rheocasting process because this alloy has excellent mechanical properties. In this work, the rheological behavior of 7075 aluminum alloy semi-solid slurry is studied through shear stress-controlled test and shear rate-controlled test. Then the constitutive parameters in Power-Law (PL) model or Carreau-Yasuda (CY) model of non-Newtonian fluid are determined. The models are used to simulate the flow behavior of 7075 aluminum alloy semi-solid slurry in Swirled Enthalpy Equilibration Device (SEED) rheocasting process. The simulation results indicate that the CY model derived from the shear rate sweep test is more suitable for simulating the flow behavior of 7075 aluminum alloy semi-solid slurry during rheocasting than the other models.

Abstract: The semi-solid slurry of 6061 aluminum alloy was prepared by the serpentine channel pouring process. The influence of graphite serpentine channel and copper serpentine channel on the slurry was comparative analyzed. The effect of pouring temperature on the slurry microstructure was also investigated. The results indicate that both copper and graphite serpentine channel can be used to prepare semi-solid slurry with spherical primary grains. Compared with a permanent casting, the microstructure of the semi-solid slurry was significantly improved and refined. With the increase of pouring temperature, the average equivalent grain diameter of the primary phase grains in the semi-solid slurry increases gradually, but the shape factor decreases gradually. When the pouring temperature increased from 675 °C to 690 °C, a high quality semi-solid slurry can be obtained. Comparing the two kinds of serpentine channel, it is found that the copper serpentine channel can make the primary grains finer, and the average equivalent grain size was 63 μm. However, the solidified shell near the inner graphite serpentine channel surface was thinner than that of the copper serpentine channel. In conclusion, the graphite serpentine channel is more suitable for preparing semi-solid 6061 aluminum alloy slurry.

Abstract: The study investigated the effects of mechanical stirring before solidification on the metallurgical structure of hypoeutectic aluminum-silicon A356. A series of stirring trials were conducted in the present study. Emphasis were placed on the morphological changes of the primary phase, which was subjected to different levels of stirring at various values of the rod material and its diameter, insertion temperature and rotation speed. It was found that when the rod was made of the same material as the molten metal, it acted as a nucleation site to generate numerous nucleated primary crystals, which separated from the rod surface continuously into the molten metal with the rotation of the stirring rod, resulting in the refinement and spheroidization of the primary crystals. The ideal semisolid slurry with homogeneous spherical and fine primary crystals could be obtained by optimizing rod insertion temperature, rotation speed and its diameter, which is a key factor in semi-solid forming.

Abstract: Semisolid slurries of four wrought alloys were fabricated via partial melting of commerical wrought aluminum alloy. Thixoforming experiments of four typical parts were performed. The results showed that a large amount of equiaxed grains before soaking in semisolid state were created due to recrystallization occurred in the continuous heating from room temperature to a given temperature above recrystallization temperature. It provides a desirable microstructure to form spheroidal grains during the next soaking process in semisolid state. The microstructure of the 2A12,7A04 and 7075 semisolid slurry consisted of fine and spheroidal grains. The elongation of the thixoformed parts were higher those of the hot-rolled plate. The UTS of the thixoformed parts were close or ever higher than those of the hot-rolled plate. Although the grain size and roundness of the 5A06 semisolid slurry are not very desirable, the mechanical properties of the thixoformed part are close or ever than those of the hot-rolled plate. The high mechanical properties of the thixoformed parts further confirmed the feasibility of short-process thixoforming route

Abstract: A201 alloy is the strongest cast aluminum alloy, but it is considered one of the most difficult aluminum alloys to cast due to its susceptibility to hot tearing during solidification. Semi-solid casting, which characterizes fine near-globular or non-dendritic grains and relatively narrow solidification range, is potential to reduce hot cracking tendency of alloys. In this present work, semi-solid slurries of A201 alloy were prepared using Swirled Enthalpy Equilibrium Device (SEED) technique and then injected into a self-designed high pressure hot tearing mold. The microstructures of A201 semi-solid slurries with different pouring temperatures were examined. Effects of different casting pressures on the hot tearing sensitivity of A201 have been investigated. This study finds that SEED is capable of producing satisfying A201 semi-solid slurries. Lower pouring temperatures produce A201 semi-solid slurries with finer and rounder grains as well as more uniform microstructure distribution. Increasing the intensification pressure significantly decreases the hot treating tendency of A201 alloy. When the pressure reaches to 90 MPa and the mold temperature of about 250 °C, the hot tearing susceptibility (HTS) index value is nearly zero, which means almost no surface cracks are found in the semi-solid A201 die casting parts.

Abstract: Semi-solid aluminum slurries have globular grains, different from traditional dendritic solidification microstructures. The mechanism responsible for the formation of these globular grains is still in dispute. Some researchers suggest that the globular grains are formed by fractured dendrites, while others report it is due to copious nucleation. This study will model the growth of the α-Al phase during the production of semi-solid slurries using the swirled equilibrium enthalpy device (SEED) process, where liquid alloy with a low superheat is poured into a steel crucible and swirled within the semi-solid region. Experimental observations have shown that the final microstructure of the slurry produced by the SEED process is relatively non-uniform, with large dendrites at surface and fine spherical particles at the center. Open source code for the phase field method has been adopted to simulate the different microstructural evolution for semi-solid alloy 357.0. The effect of localized temperatures under isothermal condition on the morphology of the α-Al particles has been investigated according to the special conditions of the SEED process. In addition, suggestions for modifying the slurry production to achieve more uniform microstructure are discussed.

Abstract: Rheological forming, a semi-solid metal forming process, is one of the manufacturing technologies for near net shape forming. The technology has attracted global academic research interests in recent years. This paper presents the current status of industrial applications of the semi-solid rheological forming technology in the China mainland. A variety of semi-solid slurry preparation techniques have been adopted including electromagnetic stirring and low superheat pouring. Dedicated semi-solid rheological forming equipment developed by the local manufacturers have been highlighted. This paper also makes an attempt to review the crucial factors for successful industrial application of the semi-solid metal forming process.

Abstract: Annular electromagnetic stirring (A-EMS) process is verified an advanced metal melt treatment technology. Application research was performed to investigate the solidification behavior of Al-Zn-Mg-Cu alloy in this study. The results indicated that uniformly fine microstructure, less composition macro-segregation and improved mechanical properties were achieved.

Abstract: A new method of helical curve duct (HCD) to prepare semi-solid slurry was investigated. The semi-solid slurry of A356, AZ91, Cu-2.21wt%Ca (0.45wt%Ce) alloys were prepared through this method of HCD. Comparison of the microstructures of slurry prepared through the helical curve duct with different structure parameters and process parameters are made and the effects of structure and process parameters on microstructures are analyzed. The results show that the melt is stirred effectively by flowing through the helical curve duct and the semi-solid slurry of alloys could be prepared through the helical curve duct process; Spherical microstructures of alloy slurry were obtained through controlling or adjusting the process parameters to control solidification conditions.

Abstract: A rheocasting technique called the Gas Induced Semi-Solid (GISS) is being developed for commercial applications in Thailand. The process creates semi-solid metal slurries by applying the injection of fine inert gas bubbles through a graphite diffuser to induce localized convection and heat extraction. The slurries are then formed into parts using different casting processes such as die casting, squeeze casting, gravity casting, and semi-solid infiltration process. This paper reports some of the current applications of the GISS forming processes, including prosthetic adaptors, lapping plates, sacrificial anodes, and armor plates. Preparation of semi-solid slurries of the alloys used in these applications, which are aluminum 356, Sn-Sb, Al-Zn-In, and 7075 alloys, is also reported and discussed.