Research on semi-solid thixoforming process of AZ91D magnesium alloy brackets for generators in JH70-type motorbikes

The investment on semi-solid die casting processes of AZ91D magnesium alloy brackets for generators in JH70-type motorbikes is introduced. The processes of low super-heat and cooling slope for the preparation of billets with non-dendritic microstructure, the remelting of billets for thixoforming and the parameters in the process of semi-sohd thixoforming have been researched. The results show that primary billets with non-dendritical structures can be prepared by forming great amount of nuclei in melt via the process of low super heat. By optimizing the remelting process through adjusting the current of the induced equipment, semi-solid billets with a structure of spherical grains were obtained from the primary billets with non-dendritical structure. The range of 580℃ to 583℃ is the proper remelting temperatures by which the billets have an expected thixotropy and can be transferred to a die-casting machine. The optimized parameters of semi-solid forming in a die-casting machine are as follows： the area of the ingate in the die is 383.5 mm^2, the speed of the pierce of the machine 5 m/s, the shot pressure of the pierce 75 MPa, and the maintenance pressure of the pierce 350 MPa. The castings of brackets for supporting generators in JH70 type motorbikes were formed by adopting the optimized processes and parameters mentioned above.

Microstructure evolution and thixoforming behavior of 7075 aluminum alloy in the semi-solid state prepared by RAP method

The effects of isothermal treatments on the microstructural evolution and coarsening rate of semi-solid 7075 aluminum alloy produced via the recrystallization and partial remelting （RAP） process were investigated. Samples of 7075 aluminum alloy were subjected to cold extrusion, and semi-solid treatment was carried out for 5-30 min at temperatures ranging from 580 to 605℃. A backward-extrusion experiment was conducted to investigate liquid segregation during the thixoforming process. The results revealed that obvious grain coarsening and spheroidization occurred during prolonged isothermal treatments. In addition, higher soaking temperatures promoted the spheroidization and coarsening process because of the increased liquid fraction and the melting of second phases. Segregation of the liquid phase caused by the difference in fluidity between the liquid and the solid phases was observed in different regions of the thixoformed specimens.

A review on steel thixoforming

Steel is a particularly challenging material to semi-solid process because of the high temperatures involved and the potential for surface oxidation.Here,the experience of semi-solid processing is reviewed and the current situation in relation to commercial application is assessed.The review will include discussion of the range of potential steel materials which are amenable to thixoformingn and identification of suitable steels;modelling of die fill and rheological properties of semi solid steel;technology considerations for industrialisation;die development and the properties of thixoformed products.

Semi-solid characteristics and thixoforming of hypereutectic Al-Si alloy

Effects of processing parameters on microstructure evolutions by mechanical stirring, procedures for obtaining thixotropy in semi solid slurries, and procedure for thixoforging component, were investigated in hypereutectic Al Si alloy. It is shown that 605 ℃ was the proper temperature for stirring treatment of this alloy, at which the coarse and plate primary Si crystals were effectively changed to globular crystals with a mean diameter of 200 μm after 50 min stirring, that billets with excellent thixotropy were obtained after 50 min remelting at 575 ℃, in which solid fraction of matrix and primary Si crystals was about 60%, and that a perfect near net shape component of disc casting was obtained by thixoforging.

Thixoforming of 6066 aluminum alloy by multi-layer spray deposition

Two thixoforming technologies of 6066 aluminum alloy (Al 1.37Si 1.37Mg 0.77Cu 0.07Mn ) produced by multi layer spray deposition process were studied. The spray formed materials are of equiaxed and very fine grain (10～20 μm). And the grain size coarsens slower than that of conventional casting materials at temperature below the liquidus, which may relate to high temperature particles distributed along the grain boundaries. Extrusion and hot pressing were used as the thixoforming processes respectively. After extrusion the materials show a microstructure of mean grain size below 20 μm without obvious recrystallization. The mechanical properties achieved via extrusion and pressing in semi solid state attain that of common wrought materials with shorter peak aging time of 4～5 h, about half of that in conventional condition. [

Stability of steel thixoforming process

To improve the industrialization of the process,the study of a thixoforming line stability was proposed.The thixoforming line is fully automated to optimize the repeatability of the experiments.Parameters of the heating cycle,the slug temperature,the tool temperature and the forming speed were studied.For each of them,a range of the expected variations in a steady-state process as well as the effects of these variations on the process itself(forming load and parts quality) were given.These variations are shown to be acceptable.Three different tools were used in the experiments.Some mathematical simulations were realized on the finite elements code Forge2008with a semi-solid constitutive law.The capacity of the model to represent the process stability was discussed.The simulation results are in agreement with the experiment results.

Characterization of thixoforming process of 100Cr6 steel

The main goal of this work is to analyze the semi-industrial process of steel thixoforming.The process was carried out using industrial equipment.This equipment consists of a heating device,industrial robots and a hydraulic press.The globular microstructure ensuring thixotropic properties was obtained using the SIMA method.It is one of the simplest and cheapest methods which could be easy applied in the case of steel alloys.In this work,the hot forged rods,commercially produced from 100Cr6 steel,were used.The first part of the work concerned the determination of the proper temperature range,for thixoforming of 100Cr6 steel.Next,some heating tests were carried out in order to obtain as uniform temperature distribution as possible.Heating process was executed using inductive heating.Microstructure analysis of heated samples reveals globular particles surrounded by liquid phase.At last,the thixoforming process was carried out using closed-die forming technique.Completely filled die cavity and good microstructure of the part show that applied process parameters were properly selected.

Numerical simulation and experiment validation of thixoforming angle frame of AZ61 magnesium alloy

Numerical simulation and experiment of thixoforming angle frame of AZ61 magnesium alloy were investigated.The results show that with the increase in punch displacement,cylinder billet firstly fills into die cavity of angle frame from feed inlet and plastic deformation occurs in touching region between billet and die cavity.After central thin wall of angle frame is created,semi-solid billet fills toward two edges.Lastly,complete plastic deformation occurs in billet,leading to complete filling of semis-olid billet.Effective strain,effective stress and billet temperature decrease with the increase in punch displacement.Effective stress decreases with the increase in billet temperature,die temperature and punch velocity.The optimal conditions decided by numerical simulation are as follows:die temperature of 450 ℃,billet temperature of 560 ℃ and punch velocity of 30 mm/s.Angle frame components with high mechanical properties such as yield strength of 225 MPa,tensile strength of 309 MPa and elongation of 21.8% and fine microstructure could be thixoformed successfully according to process parameters decided by numerical simulation.

AlTiN and AlTiON-coated hot work tool steels for tooling in steel thixoforming

X32CrMoV33 hot work tool steel samples coated with AlTiN and AlTiON were submitted to thermal cycling under conditions that approximate thixoforming of steels and to sliding wear tests at 750 ℃,measured to be the cavity surface temperature shortly after the steel slurry is forced into the thixoforming die.AlTiN and AlTiON coatings provide adequate protection against oxidation of the tool steel substrate,but fail to avoid thermal fatigue cracking.This is attributed to the extensive softening of the substrate,the thermal expansion mismatch between the hot work tool steel and the coatings and residual compressive stresses inherited from the deposition process.The impact of AlTiN and AlTiON coatings on the high temperature wear resistance,on the other hand,is favourable.The improved wear resistance is attributed to the stable,protective surface oxide films.

Characteristics of 100Cr6 bearing steel after thixoforming process performed with prototype device

A device based on a high pressure die-casting(HPDC) machine was constructed,with a capacity to produce thixo-casts from steel.After inductive heating to the required semi-solid temperature range,the samples were transported in a protective argon atmosphere to a cylinder of modified HPDC and injected into a pre-heated die.Bearing steel 100Cr6(after forging) was used as the feedstock material.The metallographic analysis of the steel showed a homogenous structure within a whole volume characterized by a grain size between 2 μm and 8 μm.Differential scanning calorimetry(DSC) analysis allowed to estimate the process temperature for thixoforming at 1 390 ?C which was attributed to about 45% of a liquid phase.With such technological parameters after the semi-solid processing the microstructure consisted of globular grains of size from 15 μm to 40 μm.The microstructure of globules indicated predominant presence of martensite(about 76% volume fraction) with residual austenite between plates.X-ray analysis confirmed that the thixo-cast samples contain mainly martensite and residual austenite.The hardness of the initial forged sample was HRC 27 and after the thixoforming process it was HRC 60,which confirms the presence of martensite and carbides.The thixo-casts were subjected to low tempering,at temperature of 150 °C for a period of 2 h,in order to remove stresses created during the process of thixoforming and to increase plasticity.The hardness after tempering was HRC 62.3.Additionally,in order to identify phases present in the thixo-casts,transmission electron microscopy(TEM) was carried out.

Thixoforming of spray deposited AlZn_ 12Cu_2Mg_2 wrought aluminum alloy in semi-solid state

The processing parameters were achieved about the thixoforming of spray deposition AlZn 12Cu2Mg2 wrought aluminum alloy in semi-solid ingots and the structures and mechanical properties of the analogue work pieces were tested. The optimum heat treatment parameters of the alloy by the optimization experiment were obtained （460℃ being the optimum solution temperature and 12-14h being the optimum artificial aging time）. The results show that AlZn 12Cu2Mg2 alloy can achieve ideal mechanical properties and elongation after solution treatment and aging treatment by semi-solid process. Under 120MPa and at 595-600℃, the yield strength and elongation of the heat-treated parts can reach 664MPa and 7.5% respectively.

Fabrication of Aluminium Matrix Composite Using Thixoforming Process for High Strength Material Components

Aluminium-based MMCs(metal matrix composites)have many potential applications in the automotive manufacturing industry,aerospace and military because the aluminum has a low density.Aluminum as a matrix with Al2O3 reinforcement has attracted interest to be developed in order to improve the mechanical property.The study carried out the formation of Al-5%Cu-4%Mg matrix with the reinforcement of Al2O3 by thixoforming process.In this paper,we studied the effect of semisolid thixoforming process on strength of Al-5%Cu-4%Mg matrix.The matrix used here was doped by Al2O3 with the volume fraction from 5%to 20%.It is found that strength of MMCs significantly increases with increasing volume fraction of Al2O3 reinforcement from 5%to 20%.This is due to a good wettability in interface region such as formation of spinel MgAl2O4 phase.Moreover,toughness of MMCs increases by process of semisolid thixoforming due to evolution of microstructure such as globular and fine grain structures.These results indicate that the thixocasting process conducted in this study could increase the value of the matrix hardness and tensile strength,so that such process opens up opportunity for application in the manufacturing industry.

Microstructure and Mechanical Properties of 7005 Aluminum Alloy Components Formed by Thixoforming

In the present research, semisolid billet of 7005 aluminum alloy was fabricated by using recrystallization and partial remelting（RAP）, then thixoformed at different isothermal temperatures, preheating temperatures and load routes. Mechanical properties and microstructure of the thixoformed product were investigated. The results showed that microstructure achieved by three-step induction heating warm extruded 7005 aluminum alloy consists of a uniform and spheroidal microstructure suitable for thixoforming.Preheating temperature of the die affected significantly the filling status of semisolid billet of 7005 aluminum alloy. Complete filling status with good surface quality was obtained at a preheating temperature of 365 ℃. Thixoformed microstructures consisting of relatively spheroidal grains illustrate the dependence of filling process on the sliding and rotating of solid grains rather than plastic deformation of solid grains. A non-uniform distribution of liquid phase was found in the different regions of the thixoformed product due to the slower adjustable velocity of solid grains as compared with liquid phase. Increase of isothermal temperatures led to a slight decrease of mechanical properties of the thixoformed product due to coarsening of solid grains. The highest yield strength, ultimate tensile strength and elongation of thixoformed components with T6 heat treatment are 237 MPa, 361 MPa and 16.8%, respectively, which were achieved at the isothermal temperature of 605℃. Load route has a significant effect on mechanical properties and microstructure of the thixoformed product. Defects, such as crack and microporosity occurred in the microstructure of the thixoformed product obtained under load route 2. It led to an obvious reduction of mechanical properties as compared with route 1. A better compatibility of deformation caused by more liquid fraction at the isothermal temperature of 612℃ is beneficial to reducing nonuniformity of liquid phase in the different regions of the thixoformed product.

Constitutive Modeling for Thixoforming of 9Cr18 Semi-solid Alloy and 3D Forecast Mapping

Thixotropic Compression tests were carried out on 9Cr18 semi-solid alloy through Gleeble-1500 thermal simulation machine. According to the experiment analysis, macro separation occurred during thixoforming. The liquid film was extruded outside to the surface and solidified to form eutectic structure. The solid particles were connected with each other and underwent plastic deformation. According to the comparison between Zhou-Guan model and modified Zhou-Guan model, it could be observed that the adding of thixotropic factor played an important role in the regression and the latter one was more credible. The modified Zhou-Guan model could well describe the thixoforming behavior. 3D forecast mapping was built for 9Cr18 semi solid alloy in thixoforming temperature range. It would provide valuable information for selecting process parameters during thixoforming in the manufacture process.

Formation of Liquid Pools Entrapped within Solid Grains of ZA27 Alloys during Partial Remelting

The investigations were performed into the formation processes of liquid pools entrapped within solid grains of three ZA27 alloys, produced respectively by either grain refinement, or traditional permanent casting or mechanical stirring, during partial remelting at semisolid temperature of 460℃. The results show that the rapid coalescence of primary grains due to merging of secondary arms during the initial stage of partial remelting is the main cause for the formation of the entrapped liquid pools. This coalescence resulted in that a high quality of eutectics, especially the 77 phase, was entrapped within the grains, and then remelted to form liquid pools during the subsequent heating. In addition, the growth of the η phase decomposed from the primary α' phase and β phase and the subsequent remelting is another cause for the refined and permanent mould casting alloys. Furthermore, the agglomeration of the solid grains also resulted in the entrapment of liquid in the interior of grains.

Effects of Cr and Cr/Mn Combined Additions on Semi-Solid Microstructures of Al-Mg-Si Alloys Produced by D-SSF Process

The effects of Cr and Cr/Mn combined additions on the semi-solid microstructure of wrought Al-Mg-Si alloys are investigated.In the Cr-added alloy,the Al-7Cr compound is formed with homogeneously distributed in theα-Al matrix after homogenization.Both of the Al-7Cr andα-Al-（12）Mn3-Si-2 dispersiod particles are found in the homogenized microstructure of the Cr/Mn-added alloy.In the semi-solid microstructures,the smallestα-Al grains are obtained in the 60% cold-rolled alloys.After prolonged holding time,theα-Al grain size of the Cr/Mn-added alloy is smaller than that of the Cr-added alloy.Heavy deformation by cold-rolling accelerates spheroidization of theα-Al grains.The D-SSF process is found to be useful to modify the microstructures of both the Cr-added and Cr/Mn-added Al-Mg-Si alloys.

Microstructural evolution of fine-grained ZA27 alloy during partial remelting

The microstructural evolution process of fined-grained ZA27 alloy during partial remelting has been investigated. The relationship between the as-cast and semi-solid microstructures has been discussed in particular. The results indicate that a semi-solid microstructure with small and spheroidal primary particles can be obtained when the ZA27 alloy is partially remelted. The microstructural evolution can be divided into four stages, the initial coarsening of the dendrites due to coalescence of dendrite arms, structural separation resulted from the melting of residual interdendritic eutectic, spheroidization due to the partial melting of solid particles and final coarsening attributed to the coalescence and Ostwald ripening. An equiaxed dendrite in the as-cast microstructure may evolve into one spheroidal particle in the semi-solid microsturucture after being partially remelted. The more equiaxed the dendrites in an as-cast microstructure are, the more spheroidal the solid particles in the semi-solid microstructure will be. Finer primary particles could be obtained if the alloy with finer as-cast microstructure was partially remelted. However, due to the coalescence effect, their sizes cannot be reduced further if the refined as-cast microstructure reached a certain extent.

Friction Stir Processing of Thixoformed AZ91D Magnesium Alloy and Fabrication of Surface Composite Reinforced by SiC_ps

The microstructural evolution characteristics of the thermomechanically affected zone （TMAZ） alloy during friction stir processing （FSP） of thixoformed （TF） AZ91D alloy were investigated. Simultaneously, a surface composite layer reinforced by SiC particles （SiCps） was prepared on the alloy by FSP and the corresponding tribological properties were examined. The experimental results indicate that dynamic recrystallization and mechanical separation （including splitting and fracture of the primary grains） are the main mechanisms of grain refinement for the TMAZ. A composite surface reinforced by uniformly distributed SiCps was prepared on the alloy. Compared with the corresponding permanent mould casting alloy and the TF alloy without composite surface, the TF alloy with composite surface has the highest wear resistance and lowest friction coefficient.

Microstructure of shear-induced thixoformed Al-4.5Cu-1.5Mg alloy via RAP and SSTT processes

In this research, the effect of the thixoforming temperature on the microstructure and mechanical properties was investigated in the thixoforming of the feedstock produced by the RAP(recrystallization and partial melting) and SSTT(semi-solid thermal transformation) processes for Al-4.5Cu-1.5Mg alloy. In the RAP process, the percentage reduction in area was approximately 35%. Thixoforming was done at 610, 620, and 630 °C. Globular microstructure was observed at all temperatures and conditions. The minimum average globule size was 39 μm, and it was obtained in the thixoforming of the feedstock produced by the RAP process in the section of 4 mm in diameter at 620 ° C after applying shear. Its corresponding compressive strength was-877.44 MPa. The maximum average globule size was 136 μm, and it was obtained in the thixoforming of the feedstock produced by the SSTT process in the section of 10 mm in diameter at 630 °C before applying shear. Its corresponding compressive strength was-769.18 MPa. The finest and most spherical globules, as well as the highest compressive strength were obtained at 620 °C in both RAP and SSTT states.

Effects of Compression Parameters on Deformation Behaviors of Semi-Solid ZA27 Alloys

An investigation was performed on the effects of semi solid compression parameters,such as strain rate,compression temperature and heating time at these temperatures on deformation behaviors of two kinds of ZA27 alloys,one was modified by Zr and the other was unmodified.The results indicate that with the increasing of the strain,the stress of the modified composite first sharply increases to a peak value,then dramatically decreases to a plateau value,and again increases till the end of deformation.But for the unmodified,after being up to a peak value,the stress only decreases slowly.As the compression temperature or the heating time decreases,or the strain rate increases,the stress level and the cracking degree of these two kinds of alloys increase.Under the same deformation conditions,the stress level and the cracking degree of the unmodified alloy are higher than those of the modified one.But there is an exception that the stress level of the unmodified alloy is minimum and smaller than that of the modified one when deformed at the low temperature of 450℃.These phenomena were mainly discussed through analyzing the microstructures under different conditions and the deformation mechanisms at different deformation stages.