Forming of thin-walled cylindrical cup by impact backward extrusion of Al-Si alloys processed by semi-solid cast and ECAP

Although rheocasting is widely used for the production of thin-walled components, thick-walled rheocast components are not yet common. In this paper, thick-walled semi-solid cast components were manufactured using serial production equipment. The aim of the investigation was to replace components made of spheroidal graphite cast iron (SGI) and conventionally cast aluminium in order to lower the weight of the truck, and still fulfill the high demands set on serial production. The rheocasting process used was a modified Rapid-S process coupled with a TX630 aluminium alloy and T5 or T7 heat treatment. Two different serial production rheocast components were fatigue tested by means of constant amplitude rig testing in order to define Wöhler curves. Moreover, multi-axial shake testing with signals recorded from proving ground was carried out. Fracture surfaces as well as metallographic samples were investigated.

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Rheology Forming Process of Cast Aluminum Alloys with Electromagnetic Applications

Solid State Phenomena ◽

10.4028/www.scientific.net/ssp.116-117.445 ◽

2006 ◽

Vol 116-117 ◽

pp. 445-448 ◽

Cited By ~ 1

Author(s):

T.W Kim ◽

C.G. Kang ◽

S.S. Kang

Keyword(s):

High Pressure ◽

Die Casting ◽

Gas Content ◽

Cast Aluminum ◽

Forming Process ◽

Cast Aluminum Alloys ◽

Low Pressure Die Casting ◽

Thin Walled ◽

Semi Solid ◽

Pressure Die Casting

This paper focuses on a rheo-forming of arm parts fabricated by an electromagnetic stirring system (EMS). This forming process takes place under high pressure of high pressure die casting and thin-walled casting is possible. Also, the productivity is higher than for low pressure die casting because of the shorter cycle time. Rheo-forming is advantageous because forming is performed in the semi-solid state with laminar flow and the gas content is low, which makes welding possible. Therefore, this paper examines arm parts with EMS and has investigated the mechanical properties after T6 and T5 heat-treatment.

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Bulk-Sheet Forming Process for Products with Thin Wall and Thick Rim

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.389.273 ◽

2013 ◽

Vol 389 ◽

pp. 273-276

Author(s):

K.H. Jung ◽

H.C. Lee ◽

S. Lee ◽

E.Z. Kim ◽

Jung Han Song

Keyword(s):

Numerical Analysis ◽

Process Design ◽

Sheet Forming ◽

Thin Wall ◽

Forming Process ◽

Forging Process ◽

Backward Extrusion ◽

One Stage ◽

Thin Walled

In this study, a novel process to forge thin walled products using bulk-sheet forming concept is developed to overcome drawbacks of a conventional multistage backward extrusion. A newly developed process design is suggested based on numerical analysis, and feasibility of one-stage forging process is discussed.

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Influence of Processing Parameters on Bonding Conditions in Backward Extrusion Forged Bonding

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.504-506.387 ◽

2012 ◽

Vol 504-506 ◽

pp. 387-392 ◽

Cited By ~ 8

Author(s):

Yoshinori Yoshida ◽

Takamasa Matsubara ◽

Keisuke Yasui ◽

Takashi Ishikawa ◽

Tomoaki Suganuma

Keyword(s):

Tensile Test ◽

Processing Parameters ◽

Expansion Ratio ◽

Cold Forging ◽

Process Conditions ◽

Backward Extrusion ◽

Metallurgical Bonding ◽

Wire Cutting ◽

Surface Expansion ◽

Cylindrical Cup

In this study, conditions of metallurgical bonding between steel and aluminum in cold forging process is investigated. Two-layered cylindrical cup of the materials is produced in cold backward extrusion in five processing velocity conditions. Small tensile test specimens are cut off at the bonding boundary in the product using a wire-cutting machine and the bonding strength on the boundary is measured in tensile test using the specimens. Fractured contact surfaces are observed with an electron microscope for investigation of bonding. Finite element analyses for the backward extrusion are conducted and surface expansion ratio and interface pressure on the boundary are calculated. The influence of process conditions, extrusion velocity and surface expansion ratio and boundary pressure, on the bonding are investigated.

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Numerical Simulation of 6061 Aluminum Alloys during the Semi-Solid Backward Extrusion

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.52-54.1532 ◽

2011 ◽

Vol 52-54 ◽

pp. 1532-1537

Author(s):

Shu Zhen Shang ◽

Gui Min Lu ◽

Xiao Ling Tang ◽

Zu Xin Zhao ◽

Wei Cao

Keyword(s):

Experimental Data ◽

Numerical Simulation ◽

Deformation Behavior ◽

Processing Parameters ◽

Stress And Strain ◽

Backward Extrusion ◽

Simulation Results ◽

Semi Solid ◽

Distribution Of Stress ◽

The Relationship

Effects of deformation temperature and strain rate on deformation behavior of semi-solid 6061 alloy were investigated on Gleeble3800 thermal-mechanical simulator. On basis of the experimental data of semi-solid 6061, a model was established to describe the relationship between the processing parameters and flow stress, which showed that the experimental results and calculation ones fitted well. It would be beneficial to realize the distribution of stress and strain during the semi-solid forming on the basis of numerical simulation technology. This research paper presented the numerical simulation results of the 6061 alloy during the backward extrusion thixoforming process.

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