scholarly journals Design of Semi-Solid Forming Tools for Producing Metal-Ceramic Interpenetrating Phase Composites

2020 ◽  
Vol 47 ◽  
pp. 1004-1009
Author(s):  
Laura Schomer ◽  
Mathias Liewald
Keyword(s):  
Metal Ceramic ◽  
Semi Solid ◽  
Forming Tools ◽  
Interpenetrating Phase Composites

Bending Strength and Fracture Behaviour of Metal-Ceramic Interpenetrating Phase Composites Manufactured by Using Semi-Solid Forming Technology

2022 ◽  
Vol 327 ◽  
pp. 111-116
Author(s):  
Laura Schomer ◽  
Kim Rouven Riedmüller ◽  
Mathias Liewald
Keyword(s):  
Bending Strength ◽  
Fracture Behaviour ◽  
Structural Characteristics ◽  
Process Window ◽  
Metallic Material ◽  
Forming Technology ◽  
Metal Ceramic ◽  
Semi Solid ◽  
The Impact ◽  
Interpenetrating Phase Composites

Interpenetrating Phase Composites (IPC) belong to a special category of composite materials, offering great potential in terms of material properties due to the continuous volume structure of both composite components. While manufacturing of metal-ceramic IPC via existing casting and infiltration processes leads to structural deficits, semi-solid forming represents a promising technology for producing IPC components without such defects. Thereby, a solid open pore body made of ceramic is infiltrated with a metallic material in the semi-solid state. Good structural characteristics of the microstructure as the integrity of the open-pore bodies after infiltration and an almost none residual porosity within the composites have already been proven for this manufacturing route within a certain process window. On this basis, the following paper focuses on the mechanical properties such as bending strength of metal-ceramic IPC produced by using semi-solid forming technology. Thereby, the impact of the significant process parameters on these properties is analysed within a suitable process window. Furthermore, a fractographic analysis is carried out by observing and interpreting the fracture behaviour during these tests and the fracture surface thereafter.

Structural Characteristics of Metal-Ceramic Interpenetrating Phase Composites Manufactured by Using Semi-Solid Forming Technology

2019 ◽  
Vol 285 ◽  
pp. 51-56 ◽  
Author(s):  
Laura Schomer ◽  
Mathias Liewald
Keyword(s):  
Composite Materials ◽  
Ceramic Body ◽  
Structural Characteristics ◽  
Interface Reactions ◽  
Forming Technology ◽  
Reinforced Composite ◽  
Mould Filling ◽  
Metal Ceramic ◽  
Semi Solid ◽  
Interpenetrating Phase Composites

Interpenetrating Phase Composites (IPC) belong to a special subcategory of composite materials and reveal enhanced properties compared to the more common particle or fibre reinforced composite materials. However, as the use of conventional manufacturing processes creates structural deficits, these IPC are not able to exploit their complete potential. In this respect, infiltration of open-pore bodies from alumina with an aluminium alloy in the semi-solid state offers great perspectives for manufacturing of IPC. In this context, this paper is focusing on significant structural characteristics of metal-ceramic IPC produced in this way by using a tool with an open die cavity. Thereby, the macroscopic mould filling, possible damage of the ceramic body, the residual porosity, the filling of microporosity of the cell walls and possible interface reactions depending on the thermal parameters of the manufacturing process were investigated in this paper.

Forming of Biocompatible Materials in the Semi-Solid State

2008 ◽  
Vol 141-143 ◽  
pp. 55-60 ◽  
Author(s):  
Levente Kertész ◽  
Mathias Liewald
Keyword(s):  
Solid State ◽  
Life Time ◽  
High Melting ◽  
Machining Time ◽  
Wear Rates ◽  
Design Concepts ◽  
Forming Temperature ◽  
Temperature Levels ◽  
Semi Solid ◽  
Forming Tools

Semi-solid processing of materials provides advantages of both forging and casting. Experiments with high-melting and biocompatible alloys aiming at a “near-net-shape” production technology recently have been conducted. Advanced trials showed, that processing of such materials by means of semi-solid forming deliver a huge potential for feasible workpiece shapes and drastically reduces machining time and subsequent surface treatment efforts. In contrast to semi-solid forming of aluminium alloys at relatively low temperature levels any processing of high-melting point alloys in the semi-solid state is much more challenging due to higher forming temperature. Commonly used tool materials provoke high wear rates due to wetting, bonding and melting processes which finally result in a very short tool life time. Thus, more apt materials and composites for forming tools and dies which can withstand corrosion, wear, tear and extreme changes in temperatures have to be found. The development of new design concepts for long-living close-to-production tools based on such new materials will be a future goal.

Thixoforming of Steel: A State of the Art from an Industrial Point of View

2008 ◽  
Vol 141-143 ◽  
pp. 25-35 ◽  
Author(s):  
Pierre Cezard ◽  
T. Sourmail
Keyword(s):  
Mechanical Properties ◽  
State Of The Art ◽  
Point Of View ◽  
Raw Material ◽  
Forming Process ◽  
Research Teams ◽  
The World ◽  
The Subject ◽  
Semi Solid ◽  
Forming Tools

Since the first research works in the end of 1980s on the semi-solid forming of steel, this process has presented a great interest and a real industrial potential. Several research teams, all over the world, have shown the feasibility of such a process. Working on the parameters which have an influence on the process, they pointed out the "technical locks" which must be overcome to allow industrialization of the process. A first and perhaps most important difficulty is the reliability of the forming tools in an industrial production context. Much work has therefore been devoted to identify ways to increase tools life. A second important point is the possibility to obtain sound microstructure and satisfactory mechanical properties. This paper is a state of the art review on the subject of the thixoforming of steel, restricted to forming of semi-solid reheated steel. Semi-solid forming process carried out after partial solidification are therefore not covered. The reader interested in such processes may refer to the review recently published by Hirt et al. [1]. The present review considers, in turn, the different steps of an hypothetical production line and their particular challenges, from the raw material to the final product.

A synthetic route for metal–ceramic interpenetrating phase composites

2006 ◽  
Vol 60 (29-30) ◽  
pp. 3723-3726 ◽  
Author(s):  
J.-S. Kim ◽  
Y.-S. Kwon ◽  
O.I. Lomovsky ◽  
M.A. Korchagin ◽  
V.I. Mali ◽  
...  
Keyword(s):  
Synthetic Route ◽  
Metal Ceramic ◽  
Interpenetrating Phase Composites

Deposition of Oxides as Tool Protection for Large Thixoforming Dies by Using the Pulsed MSIP-PVD Process

2008 ◽  
Vol 141-143 ◽  
pp. 249-254 ◽  
Author(s):  
Kirsten Bobzin ◽  
Nazlim Bagcivan ◽  
Philipp Immich
Keyword(s):  
Process Parameters ◽  
Process Development ◽  
Field Tests ◽  
Target Surface ◽  
Oxide Coatings ◽  
Bond Coats ◽  
Thin Film Coatings ◽  
Industrial Coating ◽  
Semi Solid ◽  
Forming Tools

Oxide coatings offer great potential for their use in forming operations in the semi-solid state. Advantages of these types of coatings are high resistance against abrasive wear, high hot hardness and low thermal conductivity. Nevertheless deposition by pulsed Magnetron Sputter Ion Plating-PVD for oxide coatings is quite challenging: deposition rates are low and insulating layers on the target surface can cause arcing. On laboratory scale it was possible to deposit γ-Alumina using PVD in a temperature range, where hot working steel can be utilized. The next important step in the development towards an industrial application for larger forming tools is the upscaling process to larger coating units. In this work the process development of oxide coatings on an industrial coating unit for large tools was described. To increase adhesion of oxide top-layer additional bond coats were applied. Different process parameters like oxygen content, total pressure and substrate bias were varied, to improve the performance. The relationship between coating properties and process parameters of the deposited films were characterized by X-Ray-diffraction, Nanoindentation and Scanning Electron Microscopy (SEM). By using reactive pulsed PVD-process it was possible to deposit γ-Al2O3 on large steel tools for semi-solid melt protection. The developed coatings showed for thixoforging processes of X210CrW12 an extraordinary stability in field tests. The lifetime of the permanent moulds was increased by using PVD thin film coatings as a tool protection.

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