Solid State Phenomena Vols. 116-117

Abstract: Various processing methods exist for applying agitation to a molten metal during solidification to obtain metal slurries suitable for semi-solid metal processing. . In this paper, a new technique to achieve semi-solid metal structure using agitation during solidification is reported. The technique applies a new medium and means to efficiently create semi-solid metal structures. The results of a systematic study showing the feasibility and the necessary conditions to achieve the structure are discussed.

Abstract: New manufacturing methods for metal matrix composites (MMC) are developed. Thermally sprayed metal coatings on reinforcement-fabrics are used as preforms (prepregs) for an advanced thixoforging process. The semi-solid forming and simultaneous infiltration in short cycle times offer the possibility to realize complex near net-shape geometries and reduces fiber damage to a minimum.

Abstract: Processing of light-metals in semi-solid state offers some advantages regarding process temperatures, handling of the material, but also the resulting micro-structure of the final component. Reinforcement of light-metal components with fibers or particles can be applied in order to increase elastic modulus and yield strength of the material as well as its wear resistance. But, the manufacturing of metal matrix composites by thixoforging requires the supply of raw material that shows thixotropic behavior at processing temperature and that contains a definite volume fraction of well distributed reinforcement phase. In this work, an arc wire spray process is applied for the manufacturing of semi-finished parts by coating of long-fiber fabrics and by deposition of ceramic particle containing billets. The process technique is described and the suitability of thermally sprayed matrix material for semi-solid processing is verified.

Abstract: A356 was cast into the strip by the semisolid strip casting using an unequal diameter twin roll caster. This process was one of the rheocasting. The semisolid slurry was made by a cooling slope. Solid fraction was about 5%. The casting speed was 20 m/min, and the thickness was 4.4 mm. The as-cast strip could be cold rolled down to 1 mm. The result of tension test of 1mm-thickness-T4 heat-treated strip was as below. Tensile stress was 223 MPa, 0.2 proof stress was 123 MPa and elongation was 21.8%. Deep drawing could be operated to 1 mm-thickness T4 sheet, and L.D.R was attained to 2.0. In some condition, 180 degrees bending could be operated without crack at outer surface. These results mean that semisolid roll cast A356 strip may be able to use for press forming.

Abstract: The thixoforming processes join the advantages of conventional forming technologies as forging and casting in respect of the mechanical properties and the practicable geometries. Within the framework of the Collaborative Research Centre 289 at the RWTH Aachen University intensive investigations on semi-solid processing with some steel grades have been running. For this purpose an automated thixoforging plant (thixo-cell) has been developed in a closed cooperation with several industrial partners. With this equipment multi material demonstrator components have been successfully produced by thixojoining using semi-solid X210CrW12 tool steel.

Abstract: Bühler has developed an economical way to produce high quality structural parts using conventional die casting equipment.

Abstract: Ultrasonic vibration was applied to the surface of AZ91D/CNF slurries in order to homogeneously disperse the reinforcement through the semi-solid matrix, and eliminate the clusters of nano-fibres originated during previous processes. The method utilized to produce the slurry was a modified compocasting process that generates semi-solid magnesium alloy using an inclined cooling plate and mechanical stirring. The CNF reinforcement was added in quantities varying from 1 to 3vol% and different vibration times and amplitudes were applied to the slurries under isothermal conditions. Macro and microstructure combined analysis showed the occurrence of grain refinement in the whole ingot for higher wave amplitudes at shorter times, while for lower amplitudes longer times up to 10min. were required. Vibration times over 10min were not significant to further improve the results and times up to 4min did not seem to provide any result whatsoever. The best results, however, were obtained for 16 and 18μm amplitudes. Discontinuous application of ultrasound seems to produce better results than continuous vibration. The dispersion of reinforcement seems to occur by the smash of CNF clusters due to the movement of the solid fraction present in the Mg alloy slurry, and by cavitation, responsible also for some microporosity present in the microstructures.

Abstract: A method for joining metals in the semisolid state is presented. A model alloy Sn-15%Pb was used to demonstrate the concept. By presented process, dendritic microstructure of the weld zone can be avoided. Moreover, near-weld zone of the cold worked substrates which is affected by heat would have a globular structure due to a thermomechanical treatment. The two substrates were heated up locally in the joint line to the semisolid temperature range. At this point a stirrer was introduced into the weld seam in order to mix the two sides into a single uniform joint. Localized mechanical properties of different zones were examined using Shear Punch Test (SPT), showing a good strength in the weld zone and thermomechanically affected zone.

Abstract: The continuous rheoconversion process (CRP) is a novel slurry-on-demand process that was developed at MPI/WPI in 2002. The process is based on a passive liquid mixing technique in which the nucleation and growth of the primary phase are controlled using a specially designed “reactor”. The reactor provides heat extraction, copious nucleation, and forced convection during the initial stage of solidification, thus leading to the formation of globular structures. This paper presents our recent work on the scale-up of the CRP for industrial applications. Specifically, we demonstrate an important application of the CRP to low temperature (low fraction solid) HPDC. In Part I of this paper, we present salient results on microstructural characterization of CRP processed castings vs. conventional die castings.

Abstract: Novel semisolid casting method to produce bulk metal ingots with homogeneous fine-grained structure is proposed. In the method, the fine-grained particles are subjected to partial melting and compacting. As a result, the ingot structure is constituted mainly by fine-grained particles bonded by inerlayers of solidified melt.