Solid State Phenomena Vols. 116-117

Abstract: Semi-solid forming (SSF) involves alloys with non-dendrite microstructure that contain spherical solid particles in the liquid matrix. This process is generally divided into three main steps: feedstock manufacturing, reheating and forming. Feedstock has the main effect on the cost and quality of product. Many researches have been carried out to reduce the cost of feedstock manufacturing. Slope plate is a simple semi-solid process that can reduce the cost of feedstock. In this study a Cu plate with water and without water circulation was used to investigate the effect of pouring temperature, cooling rate during casting and solidification in the mold on the microstructure. Cast ingots with optimized microstructure were reheated in various time and temperatures in semi-solid region to obtain kinetics of globularization and solid grain growth.

Abstract: Reheating process in the semi-solid state is a very important step in the thixoforming process. In this research semi-solid ductile cast iron and Al alloys (Al-2.5Si, Al356) prepared by inclined plate method, were reheated to examine the effect of reheating conditions on the microstructure and coarsening kinetics of the alloys. For ductile cast iron, solid fraction at different reheating temperatures and holding times was obtained and based on these results the optimum reheating temperature range was determined. In the case of Al alloys increase of holding time in the semi-solid state, leads to increase of liquid fraction, solid grain size and improvement of sphericity of solid particles. In addition, the results show that coarsening kinetics of microstructures of both alloys during reheating was diffusion controlled and can be mostly treated by Ostwald ripening theory.

Abstract: This paper deals with the examination of the steel grade X210CrW12 and its suitability for Thixoforming. In the semi-solid state, the microstructure of this steel consists of a homogeneous distribution of globular particles surrounded by liquid. Additionally, carbides are stabile up to fraction liquid contents of approximately 40%. After quenching, this steel reveals a globular austenitic microstructure with eutectic (former liquid phase) at the grain boundaries. Compression tests permit to determine the influence of different process parameters on the properties and the material behaviour in the semi-solid state. Their influence on the microstructure was investigated but not yet highlighted. Further investigations on this steel allow a fine-tuning to establish optimal process windows of the different thixoforming- and rheoforming- routes.

Abstract: The structural control of Al-Si alloy, which was not studied among various electromagnetic processing of materials, was considered applying the alternating current and direct current magnetic flux density. The main aim of the present study is to investigate the effects of electromagnetic vibration on the macro and microstructure of Al-Si alloy in order to develop a new process of structural control in Al-Si alloy. When the electromagnetic vibration is conducted for changing the shape of primary aluminum, at low frequency (≤ 60Hz), the shape of dendrite is changed speroidal shape. When the electromagnetic vibration is conducted for changing the shape of eutectic silicon, the fact that a morphological change of the eutectic silicon from coarse platelet flakes to fine fiber shape is observed with EMV (Electro Magnetic Vibration) process at high frequency(≥ 500Hz).

Abstract: In-situ Al-4.5Cu-5TiB2 composite plates were stir cast with TiB2 particles formed through mixed salt route. The as-cast samples with 30 volume percent liquid content were rolled in mushy state down to 2.5 and 5 percent reduction in thickness per pass. The rolled products found to be defect-free after the first pass were subjected to multiple roll passes in mushy state with identical experimental conditions, adding up to seven. The wear properties of as-cast and mushy state rolled composites were also investigated, and correlated with microstructure.

Abstract: The success of the thixoforming process depends on the possibility to confer to material, when it is found in the semisolid state, a microstructure characterized by globular particles of solid phase surrounded by a continuous film of liquid phase; such microstructure is obtainable through particular thermo-mechanical treatments. In the present research, in order to optimize the influence of process parameters in the step in which the thixotropic properties are conferred to the AA7075 aluminum alloy, the statistic technique of the Design Of Experiments (DOE) has been used. The advantages in the application of such technique are expressible in terms of reduction the times of development of process and more efficient use of resources. A Central Composite Design factorial plan with two levels has been realized to allow the evaluation of experimental error and to check the adequacy of the model. The experimental tests foreseen from the same plan have been therefore performed. Using the method of the response surfaces (RSM), the function of response has been formulated, and the analysis of the experimental data has been realized by the linear regression method. Finally, the analysis of variance (ANOVA) allowed to value the causes of variability of the results. Statistic test has been performed on the significance of single factors and their interactions.

Abstract: Back extrusion technique was employed to characterize phase segregation tendency of mechanically stirred ZA27 alloy at different deformation rates. Variation of segregation intensity with ram diameter was found to follow opposite trends at low and high ram speeds. At sufficiently high ram speeds, small rams are of better performance in minimizing segregation whereas at low ram speeds, large rams result in less pronounced segregation. In addition, increasing ram speed invariably decreases segregation degree. Back extrusion at very high shear rates provided via a Drop Extruder Apparatus capable of displacing ram at speeds in excess of 1m/s results in production of very homogeneous products in terms of solid fraction as well as size distribution of globules.

Abstract: The evolution of the microstructure of semi-solid Al-Cu alloys has been characterized during isothermal treatments in the semi-solid state by using in-situ X-ray microtomography experiments carried out at ESRF, Grenoble. This work is therefore a continuation of previous experiments reported at the 8th S2P Conference in Limassol. Quantitative data are presented dealing with changes with holding time of the solid volume fraction, of the solid-liquid interface area and of the mean and Gaussian curvatures of the solid phase. Discussion of the results is carried out on the basis of the mechanisms involved in semi-solid systems.

Abstract: Magnesium alloy AZ31, which processed by conventional rolling or extrusion, has high anisotropy of mechanical properties in its strength and elongation at room temperature. We compared the influence of differential speed rolling with conventional rolling process on microstructure and mechanical properties of commercial AZ31 sheet. Commercial AZ31 alloy sheets were processed with conventional and differential speed rolled with thickness reduction ratio of 30% at a various temperature. The elongation of AZ31 alloy, warm-rolled by differential speed rolling is larger than rolled by conventional rolling. Besides, grain size and distribution on microstructure of the conventional rolling were coarsely(~30μm) and inhomogeneously but, that those of the differential speed rolling were fine(~13μm) and homogeneously.

Abstract: In order to produce a high quality and cost effective part in the rheocasting process for an automobile industry it has been important to develop a slurry-on-demand process, which can manufacture the semi-solid slurry having a fine and globular structure of primary solid phase. The morphology of primary solid phase of semi-solid slurry is coarsened and globularized during an isothermal holding process in a solid-liquid region. Accordingly, in this paper, the microstructural evolution of semi-solid slurry during the isothermal holding at a various temperature in solid-liquid region was investigated to examine a coarsening and globularization behavior of primary solid phase. The semi-solid slurry of Al alloy was produced in a slurry maker using a multiplex-type slurry cup that we developed recently. A size of primary solid phase was the finer at the higher holding temperature, but under a constant holding time a roundness degree of primary solid phase was the lower at the lower holding temperature. Also, a coarsening rate of primary solid phase was not considered to be affected significantly by a holding temperature even though a little lower coarsening rate was obtained at the higher holding temperature.