Solid State Phenomena Vols. 116-117

Abstract: The Council for Science and Industrial Research has developed and patented a rheocasting process. The process involves the preparation of semi-solid slurries from liquid metal, by controlled cooling and MHD stirring using induction coils. An industrial prototype was designed and built to test the system in an industrial environment. A semi-solid high pressure die casting cell was set up with an industrial partner and the system was tested under normal production conditions. The production cell consisted of the CSIR rheocasting system, a six axis robot, dosing furnace and 400 ton H-400SC shot controlled Bühler HPDC machine. An engine mounting bracket originally designed for liquid HPDC was redesigned for SSM forming (casting) taking into consideration the flow and thermal behaviour of semi-solid casting process, the function of the component and the required mechanical properties. Although a full production run was not completed due to an ancillary equipment failure, sufficient castings were produced to perform preliminary evaluation of the components. The processing parameters used were, die temperature of 250°C, SSM casting temperature of 580°C ±1Cº and a piston injection velocity of 0.13 m/s. Initial evaluation showed evidence of casting defects due to a combination of factors: die design/manufacture, casting parameters and poor foundry practice. From the mechanical tests it was evident that if the die design, casting parameters and foundry practice are optimized components with adequate mechanical properties can be reliably produced.

Abstract: This work aims at studying the possibility of optimising the heat treatment cycles of parts produced using the New Rheocasting process in order to reduce the total cost of the operation, attaining good mechanical properties for high performance parts. The mechanical properties and the microstructure features of the considered A 356 alloy and the relative produced parts have been analysed and studied on samples machined both from the as cast and from the heat treated compomnents. The obtained results showed the possibility of successfully modifying the T6 heat treatment cycle with economical benefits, maintaining at the same time comparable high level properties and performances, together with good dimensional precision.

Abstract: Effects of ingate velocities and the morphology of α-particles on feeding behavior of thin plate were investigated in rheo-diecasting with H-NCM semisolid. In order to acquire various morphological characteristics, three kinds of semisolid, which had different casting parameters, were prepared. In this study, we found that the range of ingate velocity which could achieve laminar flow in thin plate was from 3.88m/s to 6.47m/s. In this range, however, the laminar flow length and the total flow length showed different results according to the characteristics of semisolid. Although the semisolid had high globularity
 the semisolid which had larger α-particles than 100 showed unstable feeding behavior in the range of stable ingate velocity.

Abstract: This investigation describes the development and evaluation of thixoformable alloys on Al-Li-Mg basis in the scope of the collaborative research center SFB 289 at RWTH Aachen University. Scandium and zirconium was added to Al-Li2.1-Mg5.5 (A1420) with the aid of DoE (Design of Experiments) and precursor billets were manufactured by pressure induction melting (PIM). To evaluate the thixoformability of the synthesized alloys high-quality semi solid processed demonstrators were manufactured by the Rheo-Container-Process. Subsequent heat treatment raised the mechanical properties to maximum values of tensile strength of 432MPa, yield strength of 220MPa and an elongation of 13%. The RCP-Process was designed for the special requirements of this high reactive alloy. The paper will present extraordinary benefits in terms of properties and process simpleness for the semi-solid processing of Al-Li alloys.

Abstract: In recent year, various rheocasting methods, other than stirring in the semisolid state, have been developed to produce a fine globular primary phase in cast alloys. These new methods, called as slurry-on-demand, involve the controlled nucleation and growth/ripening of primary phase during partial solidification. In-Ladle direct thermal control (DTC) rheocasting has been competitively and successfully developed. It requires no processing equipment outside of the casting machine, no grain refinement procedure and no additional cycling time except for cooling down to the desired casting temperature. Process concept of In-Ladle DTC rheocasting is simply based on the fact that there is slurry and mush transition in the range of liquid fraction of 0.1 to 0.6 and the fact that the transition could be controlled by controlling the shape of solid and the relative energy. This study is mainly concerned about the feasibility to achieve semisolid slurry during partial solidification only through thermal and time control, this is, by In-Ladle DTC rheocasting. Based on the optimum conditions obtained by thermal modeling, microstructural evolution of Al alloys was carried out by In-Ladle DTC rheocasting. The fluidity was also investigated by In-Ladle DTC rheocasting for Al alloys.

Abstract: The tensile properties and the microstructure of an Al-7%Si-0.6%Mg-0.5%Cu rheo-cast component were investigated. The material underwent a T5 treatment, consisting in ageing at 160, 175 and 190°C for durations ranging from 0.5 to 48h. Tensile testing indicated that the T5 treatment resulted in a relatively good level of strength and in a comparatively low ductility. In order to improve ductility, maintaining as low as possible the cost of the final component, a single solution treatment at 500°C for 4h was subsequently applied. The tensile strength and ductility of the solution treated and aged material were higher than in the T5 condition. These differences were attributed to the microstructural evolution occurring during exposure at 500°C, in particular to the spheroidization of eutectic-Si and to a more homogeneous distribution of the precipitates.

Abstract: Semisolid processing is now becoming of greater interest for the production of various parts than pressure die casting. In the rheo die casting process, the important thing is to control the solid particles behavior during the rheo die casting process. So, in this paper, to find out the effect of stirring current and stirring time on the microstructure and mechanical properties, rheo die casting experiments were performed according to the stirring current such as 0, 20, 40 and 60 A and the stirring time such as 20, 40 and 60 sec. The results to the experimental conditions were analyzed.

Abstract: Mechanical behavior of processed AZ91D magnesium alloy by equal channel angular extrusion during semi-solid isothermal compression was investigated using semi-solid isothermal compression test. The results show that there are four stages, drastic increase of true stress, drastic falling of true stress, steady stage and increase of true stress. With the increase of holding time or deformation temperature, required true stress for obtaining same true strain falls evidently and peak stress and steady stress also fall in true stress-strain curve. With increasing strain rate, steady stress also increase. Peak stress will increase or decrease with the sudden increase or fall of strain rate. During semi-solid isothermal compression, plastic deformation of semi-solid billet mainly depends on plastic deformation of solid phases and their rotation and sliding. Coarse grains occur in upper position adjacent to compression die’s surface and fine grains occur in the central and free surface positions of billets.

Abstract: This research has been investigated fluidity and microstructures characteristics of AZ 91 D alloy using new type semi-solid injection machine. To ensure good casting products, uniform temperature distribution was required during heating in the injection cylinder of this machine. So, the injection cylinder was divided with six heating zones. Then temperature distribution in the injection cylinder was precisely controlled. AZ 91 D billets were heated to the desired temperatures in the injection cylinder, and injected into the permanent mold with injection speed about 430 mm/s. Fluidity was measured by using spiral permanent mold with the cavity of 1045 mm in length and 5 mm in thickness. The fluidity test has been done with the fraction solid from 0% - 60%. The fluidity was 905 to 153 mm for fraction solid 0% to 60%, respectively. At the fraction solid from 50% to 60% microstructures are consisted of spherical solid particles and the solid particles surrounded by liquid phase. The shape of solid particles begins to change at the fraction solid of 40%.

Abstract: This study is mainly concerned about the possibility to achieve semisolid slurry during partial solidification only through thermal and time control, that is, by In-Ladle direct thermal control (DTC) rheocasting for A206 Al alloy. This is based on the fact that there is slurry and mush transition in molten metal, which is controlled by the shape of solid and the relative energy. Thermal modeling of heat behavior with respect to ladle material and ladle design was investigated by 2-dimensional finite volume method (FVM). Based on the optimum conditions obtained by thermal modeling, microstructural evolution of A206 Al alloy by In-Ladle DTC rheocasting was carried out. Also, fluidity was investigated by actual In-Ladle DTC rheocasting for optimizing conditions of A206 Al alloy.