Microstructure Design of Semi-Solid Slurry for Metal Direct Writing

Abstract:

Metal direct writing in semi-solid slurry is an innovative technology to realize low-cost printing of load-bearing parts in contrast to laser-based additive manufacturing. However, it is challenging to achieve near net-forming of 3D parts in the current stage because of the out of controlled microstructure and hence the unstable macro extrusion of the used semi-solid slurry. Here, mixed powder remelting (MPR) is introduced to actively design the characteristics of solid phases, i.e., solid fraction, shape factor, and size distribution. Specifically, high-melting-point pure Al powder served as the dispersed solid phases in the liquid phase that transformed from Al-Si alloy powder after remelting, leading to hypoeutectic Al-Si semi-solid slurry. The effectiveness of this approach was experimentally examined and kinetically modelled, to prepare semi-solid slurry with pre-set microstructure. The improved extrusion stability of semi-solid slurry can be anticipated, and it is universal for manufacturing of metal matrix composites slurry.

• Periodical: Solid State Phenomena (Volume 348)
• Pages: 33-38
• DOI: https://doi.org/10.4028/p-qdK1X5
• Online since: August 2023
• Authors: Zhong Li*, Xiao Gang Hu, Hong Xing Lu, Qiang Zhu
• Keywords: Aluminum Alloys, Metal Direct Writing, Shape Factor, Size Distribution, Solid Fraction

References

[1] T. DebRoy, H.L. Wei, J.S. Zuback, T. Mukherjee, J.W. Elmer, J.O. Milewski, A.M. Beese, A. Wilson-Heid, A. De, W. Zhang, Additive manufacturing of metallic components – Process, structure and properties, Prog. Mater. Sci. 92 (2018) 112–224.

DOI: 10.1016/j.pmatsci.2017.10.001

[2] M. Vaezi, P. Drescher, H. Seitz, Beamless Metal Additive Manufacturing, Materials (Basel). 13 (2020).

DOI: 10.3390/ma13040922

[3] C.S. Rice, P.F. Mendez, S.B. Brown, Metal Solid Freeform Fabrication Using Semi-Solid Slurries, JOM 52, 31–33 (2000).

DOI: 10.1007/s11837-000-0065-5

[4] W. Chen, L. Thornley, H.G. Coe, S.J. Tonneslan, J.J. Vericella, C. Zhu, E.B. Duoss, R.M. Hunt, M.J. Wight, D. Apelian, A.J. Pascall, J.D. Kuntz, C.M. Spadaccini, Appl. Phys. Lett. 110 (2017).

DOI: 10.1063/1.4977555

[5] A. Li, X. Liu, X. Wan, Y. Yang, Thermal behaviors and fluid flow controlling the geometry of 7075 aluminum alloy single tracks during liquid metal flow rapid cooling additive manufacturing. Int. Commun. Heat Mass Transf. 116, 104664 (2020).

DOI: 10.1016/j.icheatmasstransfer.2020.104664

[6] X. Luo, Q. Yan, Z. Li, Effect of the pouring temperature by novel synchronous rolling-casting for metal on microstructure and properties of ZLl04 alloy, J. Mater. Res. 31 (2016) 2524–2530.

DOI: 10.1557/jmr.2016.233

[7] Q. Zhang, H. Li, B. Han, K. Huang, X. Fang, Z. Chen, A distinctive Pb-Sn semi-solid additive manufacturing using wire feeding and extrusion, J. Manuf. Process. 80 (2022) 247–258.

DOI: 10.1016/j.jmapro.2022.06.006

[8] D.D. Lima, K. N. Campo, S. T. Button, R. Caram, 3D thixo-printing: A novel approach for additive manufacturing of biodegradable Mg-Zn alloys. Mater. Des. 196, 109161 (2020).

DOI: 10.1016/j.matdes.2020.109161

[9] L. Englert, A. Klumpp, A. Ausländer, V. Schulze, S. Dietrich, Semi-solid wire-feed additive manufacturing of AlSi7Mg by direct induction heating. Addit. Manuf. Lett. 3, 100067 (2022).

DOI: 10.1016/j.addlet.2022.100067

[10] J.Y. Hascoët, J. Parrot, P. Mognol, E. Willmann, Induction heating in a wire additive manufacturing approach. Weld. World 62, 249–257 (2018).

DOI: 10.1007/s40194-017-0533-y

[11] S. Finke, F.K. Feenstra, Solid freeform fabrication by extrusion and deposition of semi-solid alloys. J. Mater. Sci. 37, 3101–3106 (2002).

[12] D.B. Spencer, R. Mehrabian, M.C. Flemings, Rheological behavior of Sn-15 pct Pb in the crystallization range. Metall. Trans. 3, 1925–1932 (1972).

DOI: 10.1007/bf02642580

[13] W. Qu, J. Chen, Z. Li, M. Luo, H. Lu, X. Hu, Q. Zhu, Rheological modeling and simulation of semi-solid slurry based on experimental study. Scr. Mater. 220 (2022) 114932.

DOI: 10.1016/j.scriptamat.2022.114932

[14] X.G. Hu, Q. Zhu, H. V. Atkinson, H.X. Lu, F. Zhang, H.B. Dong, Y.L. Kang, A time-dependent power law viscosity model and its application in modelling semi-solid die casting of 319s alloy. Acta Mater. 124 (2017) 410–420.

DOI: 10.1016/j.actamat.2016.11.031

[15] A.H. Ahmad, S. Naher, S.N. Aqida, D. Brabazon, Routes to Spheroidal Starting Material for Semisolid Metal Processing. Comprehensive Materials Processing 5, 135-148, (2014).

DOI: 10.1016/b978-0-08-096532-1.00515-x

[16] S. Nafisi, R. Ghomashchi, The microstructural characterization of semi-solid slurries. JOM 58, 24–30 (2006).

DOI: 10.1007/s11837-006-0175-9

[17] B. Niroumand, K. Xia, 3D study of the structure of primary crystals in a rheocast Al-Cu alloy. Mater. Sci. Eng. A 283, 70–75 (2000).

DOI: 10.1016/s0921-5093(00)00619-5

[18] L. Gao, Y. Harada, S. Kumai, Analysis of microstructure evolution and precise solid fraction evaluation of A356 aluminum alloy during partial re-melting by a color etching method. J. Mater. Sci. 47, 6553–6564 (2012).

DOI: 10.1007/s10853-012-6585-x

[19] X.G. Hu, Z.H. Hu, W.Y. Qu, X.W. Li, Z. Li, Y. Zhou, S.P. Midson, Q. Zhu, A novel criterion for assessing the processability of semi-solid alloys: The enthalpy sensitivity of liquid fraction. Materialia 8 (2019).

DOI: 10.1016/j.mtla.2019.100422

[20] X.G. Hu, Q. Zhu, H.X. Lu, F. Zhang, D.Q. Li, S.P. Midson, Microstructural evolution and thixoformability of semi-solid aluminum 319s alloy during re-melting, J. Alloys Compd. 649 (2015) 204–210.

DOI: 10.1016/j.jallcom.2015.07.121