Werkstückerwärmung für das Thixoforming*/Heating workpieces for Thixoforming - Using inductor as sensor for monitoring the heating process of semi-solid material

2017 ◽  
Vol 107 (05) ◽  
pp. 340-345
Author(s):  
J. Uphoff ◽  
A. Lechler ◽  
A. Prof. Verl
Keyword(s):  
Solid State ◽  
Solid Fraction ◽  
Material Properties ◽  
Solid Material ◽  
Heating Process ◽  
Inductive Heating ◽  
Inductor Coil ◽  
Specific Material ◽  
Semi Solid

Das Thixoforming nutzt bei der Formgebung besondere Materialeigenschaften zur Herstellung metallischer Bauteile. Die verwendeten Legierungen müssen dazu in den sogenannten teilflüssigen Bereich erwärmt werden. Das Einstellen des geforderten Fest-Flüssig-Verhältnisses stellt besondere Anforderungen an die Erwärmung. Betrachtet werden verschiedene Messverfahren, welche die Induktorspule bei der induktiven Erwärmung als Sensor nutzen.   Thixoforming uses specific material properties for shaping metal workpieces. For this purpose, the alloys need to be heated to the so-called semi-solid state. The adjustment of the desired semi-solid fraction imposes high requirements on the heating process. Various measurement principles, which use the inductor-coil as a sensor in inductive heating processes, are presented.

Steel Grades Adapted to the Thixoforging Process: Metallurgical Structures and Mechanical Properties

2006 ◽  
Vol 116-117 ◽  
pp. 712-716 ◽  
Author(s):  
Marc Robelet ◽  
Ahmed Rassili ◽  
Dirk Fischer
Keyword(s):  
Mechanical Properties ◽  
Liquid Fraction ◽  
Solidus Temperature ◽  
Process Temperature ◽  
Heating Process ◽  
Work Piece ◽  
Inductive Heating ◽  
Steel Grades ◽  
Automotive Part ◽  
Semi Solid

Thixoforming of steel offers the advantages of casting technology in combination with high mechanical strength that can only be achieved by forging. The progress in establishing this technology in industry depends on the success in the development of suitable steel grades. Recent investigations dealt with the development of steel grades that are especially adapted to the thixoforming process. For this, alloys were developed with a lower solidus temperature and a wider process temperature range compared to classic forging steels. In consequence, the inductive heating process is more tolerant to inaccuracies and for a given liquid fraction the process temperature window is easier to handle. It is desired to obtain great degrees of deformation at rather low forming forces as these parameters determine the size of the needed presses. This behaviour is affected by the present liquid fraction in the slug and the heat transfer between work piece and die. It was detected that variations of the forming force have a direct influence on the quality of the thixoformed parts. In order to make the thixoforming technology of steels competitive versus other forming technologies, the parts must show a favourable microstructure and thus, good in-use properties. In this paper various solutions are compared. The main results obtained in the optimization research, namely, the steel grades adapted to semi-solid forming, the resulting process parameters and the mechanical properties of thixoforming parts will be presented for two exemplary steel grades. By producing a real automotive part, thixoforging of steels with regard to the adapted materials and to the ongoing industrial implementation of this process is proved.

Modelling Semi-Solid Behaviour and Brittle Temperature Range

2019 ◽  
Vol 285 ◽  
pp. 361-366 ◽  
Author(s):  
Khalil Traidi ◽  
Véronique Favier ◽  
Philippe Lestriez ◽  
Karl Debray ◽  
Laurent Langlois ◽  
...  
Keyword(s):  
Solid State ◽  
Material Properties ◽  
Solid Phase ◽  
Thermal Conditions ◽  
Tensile Tests ◽  
Internal Variable ◽  
Temperature Dependent ◽  
Brittle Transition ◽  
Semi Solid ◽  
First Time

In this paper, a new elastic viscoplastic micromechanical modelling is proposed to represent the semi-solid behaviour and predict the ductile-brittle transition of the C38LTT near the solidus. It is based on a viscoplastic modelling previously presented in [1]. The originality of the new model comes from three main enhancements: the transition between the solid state and the semi-solid state was included meaning that the material properties were taken temperature-dependent, the elastic properties was taken into account similarly as [2] and the evolution of the internal variable describing the degree of agglomeration of the solid phase was enhanced. The model was implemented in the commercial software FORGE©. Tensile tests representing the experimental thermal conditions and obtained using a GLEEBLE© machine were simulated. The comparison of the predicted and experimental results shows that, for the first time to our knowledge, the three steps of the load-displacement response and ductile-brittle transition were successfully described.

Inductive Reheating of Steel Billets into the Semi-Solid State Based on Pyrometer Measurements

2006 ◽  
Vol 116-117 ◽  
pp. 734-737 ◽  
Author(s):  
Alexander Schönbohm ◽  
Rainer Gasper ◽  
Dirk Abel
Keyword(s):  
Solid State ◽  
Measurement Errors ◽  
Liquid Fraction ◽  
Solidus Temperature ◽  
Measurement Data ◽  
Heating Process ◽  
Production Environment ◽  
Loop Control ◽  
Control Scheme ◽  
Semi Solid

The aim of the paper is to demonstrate a control scheme by which it is possible to reproducibly reheat steel billets into the semi-solid state. Usually a heating program is used to reheat the billet into the semi-solid state. Our experiments showed that this control scheme leads to varying semi-solid fractions from one experiment to the next. To gain information about the billet’s state its temperature is often used since there is a known relationship between the temperature and the liquid fraction. Direct measurement of the temperature via thermocouples is not feasible in a production environment, therefore a radiation pyrometer has been used as a contact-less measurement device. The accuracy of the pyrometer depends heavily on the exact knowledge of the radiation coefficient, which can vary from billet to billet due to different surface properties and which is subject to change during the heating process. These uncertainties prohibit the implementation of a closed-loop control scheme since the exact temperature cannot be measured with the required accuracy. In order to be independent of the measurement errors the proposed control scheme only relies on the slope of the temperature. By detecting the distinct change of slope which occurs when the solidus temperature is crossed, the beginning of the melting process can be determined. The energy fed to the billet from this point onward determines the resulting liquid fraction. By detecting the entry into the solidusliquidus interval and then feeding the same amount of energy to each billet, it is guaranteed that the billet reaches the desired liquid fraction even by uncertain absolute value of the temperature and by small variations of the alloy composition. For the experiments the steel alloy X210 has been used and measurement data demonstrate the feasibility of the proposed control scheme.

K-0738 Dynamic Compressive Mechanical Properties of High Solid Fraction Aluminum Alloy in the Semi-solid State

2001 ◽  
Vol I.01.1 (0) ◽  
pp. 365-366
Author(s):  
Shusuke NAKANO ◽  
Toshiji MUKAI ◽  
Masahide KOHZU ◽  
Shigenori TANABE ◽  
Kenji HIGASHI
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Solid State ◽  
Solid Fraction ◽  
High Solid ◽  
High Solid Fraction ◽  
Semi Solid

THERMAL STABILITY AND SPECIFIC MATERIAL PROPERTIES OF NANOSYSTEMS

2000 ◽  
Vol 14 (17n18) ◽  
pp. 621-629 ◽  
Author(s):  
M. RIETH ◽  
W. SCHOMMERS ◽  
S. BASKOUTAS
Keyword(s):  
State Physics ◽  
Thermal Stability ◽  
Solid State ◽  
Standard Model ◽  
Material Properties ◽  
Harmonic Approximation ◽  
Ordered Structure ◽  
Solid State Physics ◽  
The Standard Model ◽  
Specific Material

Various material properties, which are well defined and clearly fixed for macroscopic systems, get a modified significance in nanophysics and nanotechnology, respectively. We show, as an example, that the temperature behavior of nanosystems is considerably changed when we go from macroscopic systems to those of nanometer size. It is pointed out that the standard model of solid-state physics (ordered structure, harmonic approximation) is in general not sufficient for the description of nanosystems.

Microstructure Evolution of Deformed Magnesium Alloy in Semi-Solid State

2005 ◽  
Vol 488-489 ◽  
pp. 313-316
Author(s):  
Sen Yuan ◽  
Wu Xiao Wang ◽  
Bai Ling Jiang
Keyword(s):  
Solid State ◽  
Magnesium Alloy ◽  
Microstructure Evolution ◽  
High Energy ◽  
Mg Alloy ◽  
Continuous Heating ◽  
Heating Process ◽  
Semisolid State ◽  
Semi Solid ◽  
Temperature Time

Magnesium alloy slurry was prepared using Strain-Induced Melt Activation(SIMA) technique. The samples were quenched into water so as to fix the high temperature instantaneous microstructures. The microstructure evolution of compressed deformation Mg alloy is studied in the process of continuous heating and iso-temperature of semi-solid state. The results indicate that deformed Mg alloy (AZ91) has first occurred to have the conversion of dendrite crystal-oriented isometric crystals in the continuous heating process. When the temperature rises to the range of semisolid state, the region with high energy at the pressed stripes begins to melt, showing that the cellular structures emerge in the crystal boundary and melting micro-pool phenomena appear within the crystals. With the iso-temperature time in semisolid state prolongs, the isometric crystals can be gradually converted into spherical crystal grains.

Flatness Based Control of Inductive Heating of X210CrW12 into the Semi Solid State

2008 ◽  
Vol 141-143 ◽  
pp. 127-132 ◽  
Author(s):  
Rainer Gasper ◽  
Alexander Schönbohm ◽  
Manfred Enning ◽  
Dirk Abel
Keyword(s):  
Solid State ◽  
Inductive Heating ◽  
Target Temperature ◽  
Uniform Temperature ◽  
Temperature Behaviour ◽  
Semi Solid ◽  
The One ◽  
Feedstock Material ◽  
Outer Area ◽  
Over Time

The inductive heating of the feedstock material is a very important step in the processing of semi solid metals. On the one hand, the billet has to be heated as fast as possible to the target temperature. On the other hand, it must be guaranteed that the outer area does not begin to melt prematurely. Also, at the end of the heating the billet should have an uniform temperature distribution in order to obtain good forming results. A flatness based control will be presented to calculate the induced power over time trajectory from a desired trajectory for the temperature in the middle of the billet. The temperature trajectory has to be chosen so that the billet has the desired temperature behaviour. Experimental results will be shown for the flatness based inductive heating of X210CrW12 just below the semi solid state.

Influence of Si and Mg Contents on the Mechanical Behavior of Al-Mg-Si Alloys in the Semi-Solid State under Isothermal and Non-Isothermal Conditions

2011 ◽  
Vol 690 ◽  
pp. 73-76
Author(s):  
Eliane Giraud ◽  
Michel Suéry ◽  
Michel Coret
Keyword(s):  
Solid State ◽  
Aluminum Alloys ◽  
Mechanical Behavior ◽  
Solid Fraction ◽  
Solid Alloy ◽  
Isothermal Conditions ◽  
Formation Of Cracks ◽  
Semi Solid ◽  
Si Content ◽  
Mg Content

The shear behavior of aluminum alloys containing increased amounts of Si or Mg compared with the 6061 alloy has been investigated by carrying out isothermal and non-isothermal tests in the mushy state during solidification. In isothermal conditions, it is shown that (i) an increase in Mg content leads to a more resistant semi-solid alloy compared with the 6061 alloy for the same solid fraction and (ii) an increase in Si content leads to a more brittle mushy alloy. In non-isothermal conditions, stress increases continuously with decreasing temperature with the formation of cracks for some compositions. This study shows that an increase in Mg content seems to be the most appropriate solution to reduce the formation of cracks in a solidifying 6061 alloy.

Modeling of the Semi-Solid Material Behavior and Analysis of Micro-/Mesoscale Feature Forming

2006 ◽  
Vol 129 (2) ◽  
pp. 237-245 ◽  
Author(s):  
Gap-Yong Kim ◽  
Muammer Koç ◽  
Rhet Mayor ◽  
Jun Ni
Keyword(s):  
Solid Fraction ◽  
A356 Alloy ◽  
Structural Evolution ◽  
Solid Material ◽  
Material Behavior ◽  
Flow Rule ◽  
Stress Model ◽  
Forming Process ◽  
Mesoscale Feature ◽  
Semi Solid

One of the major challenges in simulation of semi-solid forming is characterizing the complex behavior of a material that consists of both solid and liquid phases. In this study, a material model for an A356 alloy in a semi-solid state has been developed for high solid fractions (>0.6) and implemented into a finite element simulation tool to investigate the micro-/mesoscale feature formation during the forming process. Compared to previous stress models, which are limited to expressing the stress dependency on only the strain rate and the temperature (or the solid fraction), the proposed stress model adds the capability of describing the semi-solid material behavior in terms of strain and structural evolution. The proposed stress model was able to explain the strain-softening behavior of the semi-solid material. Furthermore, a simulation model that includes the yield function, the flow rule, and the stress model has been developed and utilized to investigate the effects of various process parameters, including analysis type (isothermal vs nonisothermal), punch velocity, initial solid fraction, and workpiece shape (“flat” versus “tall”) on the micro-/mesofeature formation process.

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