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Thixoforming: Semi-solid Metal Processing

Thixoforming: Semi-solid Metal Processing

Gerhard Hirt (Editor), Reiner Kopp (Editor)

ISBN: 978-3-527-62397-6

Feb 2009

474 pages

$208.99

Description

Offering a sound technological overview, while also including the fundamental aspects, this book provides the knowledge needed to master the highly challenging process characteristics for successful application in industrial production. It summarizes the first-hand experience gained from twelve years of collaborative research covering materials science, rheology, casting and forming, control and surface technology as well as the modeling of flow behavior, tool engineering and systems engineering, and thus treats all the vital aspects of this field.
For materials scientists, physicists, engineers, and those working in the metal processing industry.
Preface
SEMI-SOLID FORMING OF ALUMINIUM AND STEEL ¿ INTRODUCTION AND OVERVIEW
Introduction
Early Work on Flow Behaviour and Technology Development
Today¿s Technologies of Semi-Solid Metal Forming

PART I: Material Fundamentals of Metal Forming in the Semi-Solid State

METALLURGICAL ASPECTS OF SSM PROCESSING
Introduction
Temperature Sensitivity S* and Solid-Liquid Fraction
Slurry Formation in the Rheo- and Thixo-Routes
Proneness to Segregation and Hot Tearing
Impact of Variations in Alloy Composition
Conclusion
MATERIAL ASPECTS OF STEEL THIXOFORMING
Introduction
Background
Alloying Systems
Structural Parameter Development and Material Selection
Melting Behaviour
Microstructure Analysis and Material Properties
Conclusions
DESIGN OF Al AND Al-Li ALLOYS FOR THIXOFORMING
Production of Raw Material for Thixoforming Processes
Chemical Grain Refinement of Commercial Thixoalloys
Fundamentals of Aluminium-Lithium Alloys
Development of Aluminium-Lithium-Alloys for Semi-Solid Processing
Consideration of the Forming Pressure on Thixoalloy Development
Preparation of Principle Components from Al-Li Thixoalloys
Production of Al-Li Demonstrators by Rheocasting
Recycling of Aluminium-Lithium Alloys from Thixoforming Processes
THERMOCHEMICAL SIMULATION OF PHASE FORMATION
Methods and Objectives
Calculations for the Tool Steel X210CrW12
Calculations for the Bearing Steel 100Cr6
Calculations for the High-Speed Steel HS6-5-2

PART II: Modelling the Flow Behaviour of Semi-Solid Metal Alloys

MODELLING THE FLOW BEHAVIOUR OF SEMI-SOLID METAL ALLOYS
Empirical Analysis of the Flow Behaviour
Numerical Modelling of Flow Behaviour
Simulation of Cooling Channel
A PHYSICAL AND MICROMECHEMICAL MODEL FOR SEMI-SOLID BEHAVIOUR
Introduction
Basic Concepts of Micromechanical and Homogenization
Modelling Semi-Solid Behaviour
Results and Discussion
Conclusion

PART III: Tool Technologies for Forming of Semi-Solid Metals

TOOL TECHNOLOGIES FOR FORMING OF SEMI-SOLID METALS
Introduction ¿ Suitable Tool Concepts for the Thixoforming Process
Thin-Film PVD/PECVD Coating Concepts for Die Materials
PVD and PECVD Coating Technologies
Multifunctional PVD Composites for Thixoforming Moulds
Developing Al2O3 PECVD Coatings for Thixoforming Moulds
Bulk Ceramic Forming Tools
Conclusions and Perspectives

PART IV: Forming of Semi-Solid Metals

RHEOCASTING OF ALUMINIUM ALLOYS AND THIXOCASTING OF STEELS
Casting of Semi-Solid Slurries
SSM Casting Processes
Thixocasting of Steel Alloys
Rheoroute
Assessment and Outlook
THIXOFORGING AND RHEOFORGING OF STEEL AND ALUMINIUM ALLOYS
Introduction
Forging in the Semi-Solid State
Heating and Forming Operations
Simulation of the Thixoforming Process
Conclusion
THIXOEXTRUSION
Introduction
State of the Art
Tool Concepts
Isothermal Thixoextrusion
Non-Isothermal Thixoextrusion
Conclusion