Semi-Solid Metal Processing
Semi-Solid Metal Processing
Introduction
Discovered at MIT
in 1971 During study of hot tearing of steel during solidification Modeled by Sn-15Pb alloy using Coeutte Rheometer
Property exploited is
Rheology
Steady state rheology (Rheology) Transient state rheology (Pseudoplasticity) Time dependent rheology (Thixotropy)
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holding
Low temperature eutectic phase melts in semi-solid range Highly stressed grain boundaries favours wetting of grains with liquid Grain become globular to reduce curvature and liquidsolid interface energy
Introduction
Characteristics of Slurry
Solidification mechanism in the solid-liquid range i.e. nucleation and growth mechanisms
April 30, 2009
Liquid
Solid
Composition, Time
Alloy Characteristics
Solidification range Low melting point
phase/eutectic phase Temperature Sensitivity of solid fraction Castability Potential for aging etc.
Introduction
Classification suggested by Flemings et.Al. Rheocasting Shearing the liquid while cooling from liquid to liquid solid range and casting a net-shape product Thixocasting Shearing a partially melted suitable precursor in semisolid range Compocasting Shearing a miscible or immiscible mixture of composite in the solid-liquid range
Processing Techniques
Techniques for feed stock
Mechanical Stirring Megnatohydrodynamic (MHD) Stirring Stress Induced and melt Activated (SIMA) Process Spray Forming Liquidus Casting Ultrasonic treatment Grain refienment etc.
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Mechanical Stirring Developed at MIT Stirring of liquid alloy while controlled cooling in the semisolid range using auger, impeller or paddle Batch type or continuous process For Rheocasting and Thixocasting
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Patented by Alumax Inc. Vigorous stirring by rotating magnetic field within the mould Normally for producing feedstock for thixocasting Disintegrated fine dendrites which convert to globular grains on partial melting
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Stress Induced and Melt Activated (SIMA) Process Severe deformation of precursor results in residual stresses On heating recrystallisation occurs On partial melting low melting point phase becomes liquid High residual stress favours wetting of grain boundaries Higher curvature and liquid-solid interface energy favours globular grain morphology
Longer holding time favours coarsening and agglomeration which deteriorate semisolidprocessability
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Liquidus Casting Pouring of melt at near-liqudus temperature Higher rate of Nucleation favouring fine grain size
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Rheocasting
Non-dendritic ally slurry obtained from shearing while cooling from liquid state Mechanical stirring MHD Stirring New Rheocasting (NRC)
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Thixocasting Thixoforging
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Thixomoulding Simultaneous heating and shearing of solid feedstock in a chamber by rotating barrel Designed for Mg alloy Controlled atmosphere Similar to injection moulding
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Rheomoulding
Vigorous Shearing of liquid alloy using screw type drive while cooling Similar to Injection moulding Suitable even for immiscible alloy formation and processing
Commercial features
Advantages
Energy efficient Production rate compete that for pressure die casting Smooth die filling with no air entrapment favouring product soundness Lower processing temperature Lower Impact to the die Reduced solidification shrinkage
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Commercial features
Disadvantages
Relatively higher feedstock material cost Precise control of operating condition is required. Liquid segregation may occur as a result of non-uniform heating
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Commercial features
Potential Applications Replacement of permanent mould parts to eliminate machining and finishing Pressure tight parts such as master brake cylinders, fuel rails, air conditioner compressor housing etc. High strength parts such as engine mounts, tie rods etc. Wear resistant parts made from hypereutectic alloys such as compressor piston, brake drums, gear shift levers etc. Forged parts requiring excessive tooling
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Commercial features
Current Applications/Products
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Commercial features
Control arms for Steering Fiat Engine bracket Semi-solid Metal processing by Dr. Muhammad Kamran April 30, 2009
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Future Developments
Process development
structure Alloy development Simulation studies of process Viable process for steel and Cast Iron
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