Numerical Simulation on Thixocasting Process of Auto Box-Like

2011 ◽  
Vol 341-342 ◽  
pp. 177-182 ◽  
Author(s):  
Van Luu Dao ◽  
Sheng Dun Zhao ◽  
Wen Jie Lin ◽  
Yu Qiu Chen
Keyword(s):  
Main Process ◽  
Forming Process ◽  
Billet Temperature ◽  
Forming Technology ◽  
Initial Billet ◽  
Near Net Shape ◽  
Net Shape Forming ◽  
Ram Speed ◽  
Semi Solid ◽  
The Impact

Semi-solid metal processing (thixoforming) is a potential forming technology, which can realize near-net-shape forming process with good quality in one forming step. In this study, semi-solid casting (thixocasting) was used to form the auto box-like. Based on Power Law Cut-Off (PLCO) model and finite element code Procast software, the thixocasting process was modeled and simulated. The impact of main process parameters such as initial billet temperature, ram speed as well as die temperature on the thixocasting process was studied. The results show that thixocasting process can be used in forming auto box-like.

Impact of Process Parameters on the Auto Claw-Pole Thixoforming Process

2011 ◽  
Vol 295-297 ◽  
pp. 1625-1630 ◽  
Author(s):  
Van Luu Dao ◽  
Sheng Dun Zhao ◽  
Wen Jie Lin ◽  
Xiao Mei Yuan
Keyword(s):  
Process Parameters ◽  
Hot Forging ◽  
Main Process ◽  
Forming Process ◽  
Billet Temperature ◽  
Forming Technology ◽  
Punch Speed ◽  
Initial Billet ◽  
Die Temperature ◽  
The Impact

Thixoforming of steel is a potential forming technology, which can realize near-net-shape forming process with good quality in one forming step. In this paper, thixoforming process was used to replace the conventional hot forging process to form the auto claw-pole. The finite element code Forge2008Ó was used to simulate the auto claw-pole thixoforming process. The impact of three main process parameters such as initial billet temperature, punch speed and die temperature on the forming process were investigated. The reasonable process parameters for the auto claw-pole thixoforming were obtained: initial billet temperature 1430~1440°C, punch speed 100~200mm/s and die temperature 300~400°C.

Numerical Simulation of the Auto Claw-Pole Thixoforming Process

2011 ◽  
Vol 66-68 ◽  
pp. 1605-1610
Author(s):  
Van Luu Dao ◽  
Sheng Dun Zhao ◽  
Wen Jie Lin
Keyword(s):  
Complex Geometry ◽  
Hot Forging ◽  
Strong Impact ◽  
Forming Process ◽  
Billet Temperature ◽  
Punch Speed ◽  
Initial Billet ◽  
Near Net Shape ◽  
Net Shape Forming ◽  
Die Temperature

Thixoforming is an effective near-net-shape forming process to produce components with complex geometry and in fewer forming steps. In this study, thixoforming was used to replace the conventional hot forging to form the auto claw-pole. The finite element code Forge2008Ó was used to simulate the auto claw-pole thixoforming process. The results show that initial billet temperature, punch speed, die temperature and friction have strong impact on the forming process. Finally, the reasonable process parameters for the auto claw-pole thixoforming were obtained: initial billet temperature 1430~1440°C, punch speed 100~200mm/s and die temperature 300~400°C.

Calculation of the Nucleation Temperature during Gas Horizontal Atomization Stage in the Spray Rolling of 7050 Aluminum Alloy

2013 ◽  
Vol 700 ◽  
pp. 27-30
Author(s):  
Feng Xian Li ◽  
Xia Luo
Keyword(s):  
Heat Transfer ◽  
Aluminum Alloy ◽  
Droplet Diameter ◽  
Solidification Process ◽  
Nucleation Temperature ◽  
Forming Technology ◽  
7050 Aluminum Alloy ◽  
Near Net Shape ◽  
Net Shape Forming ◽  
Semi Solid

Spray rolling is a novel metallic semi-solid near-net-shape forming technology. This paper describes the qualitative influence of the key process parameters on the nucleation temperature during gas horizontal atomization stage in the spray rolling of 7050 aluminum alloy. The Newtonian heat transfer formulation has been coupled with heterogeneous nucleation, as well as the special solidification process. Results show that the droplet diameter has remarkable influence on nucleation temperature during spray rolling of 7050 aluminum alloy compared with that of wetting angle. The nucleation temperature approximately is 878K.

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.

Characterization of Al3Fe Particle within Al-Al3Fe Functionally Graded Material Fabricated by Semi-Solid Forming

2005 ◽  
Vol 475-479 ◽  
pp. 1503-1506 ◽  
Author(s):  
Koichi Matsuda ◽  
Yoshimi Watanabe ◽  
Kazuhisa Yamagiwa ◽  
Yasuyoshi Fukui
Keyword(s):  
Volume Fraction ◽  
Functionally Graded ◽  
Shore Hardness ◽  
Graded Materials ◽  
Before And After ◽  
Graded Material ◽  
Near Net Shape ◽  
Net Shape Forming ◽  
Semi Solid

Near net shape forming of Al-Al3Fe functionally graded materials (FGMs) have been studied. FGM billets fabricated by a centrifugal method were extruded under the condition of a mixture of molten Al eutectic and solid Al3Fe particles. Both distribution and profile of Al3Fe particles were characterized by and the variation of volume fraction of Al3Fe particles was observed. Shore hardness of the Al matrix was also measured to evaluate the strength of the FGM before and after the semi-solid forming associated with the character of distributed Al3Fe particles. It was confirmed that Shore hardness increased with increasing the volume fraction of Al3Fe particles and after the semi-solid forming than before. This was due to the fact that Al3Fe particles after the semi-solid forming became fine by shear stress introduced by liquid Al flow.

Experimental Research on the Semi-Solid Formability of 7A09 Aluminum Alloy Impeller

2011 ◽  
Vol 189-193 ◽  
pp. 3852-3856
Author(s):  
Fei Han ◽  
Wei Wei Wang ◽  
Shou Jing Luo ◽  
Zhi Ming Du
Keyword(s):  
Heating Temperature ◽  
Hydraulic Press ◽  
Holding Time ◽  
Forming Process ◽  
Forming Technology ◽  
Preheating Temperature ◽  
Complicated Geometry ◽  
Semi Solid ◽  
Wrought Aluminum Alloys ◽  
Wrought Aluminum

The impeller is an important component applied in airplanes, ships and weapons. It is difficult to form the complicated geometry of the impeller by using the conventional forging and casting technology. Semi-solid forming is a promising forming process that can produce complicated and high-quality components of wrought aluminum alloys. In this paper, the formability of the impeller was investigated by using advanced semi-solid forming technology and self-designed combined die, as well as quick forging hydraulic press. Experimental results show that the formability of the impeller increases with the increase of reheating temperature and holding time of the billet. When heating temperature and holding time during the pretreatment of the billet were 620°C and 25 min respectively, reheating temperature and holding time of the billet before thixoforging were 600°C and 90 min respectively, preheating temperature of the die was 320°C , the impeller was formed perfectly on the quick forging hydraulic press.

Fügen von Aluminium- und Kohlenstofffaserstrukturen*/Joining of aluminium and carbon fibre structures - An innovative joining technology based on semi-solid forming strategies

2017 ◽  
Vol 107 (10) ◽  
pp. 743-747
Author(s):  
M. Prof. Liewald ◽  
L. Marx
Keyword(s):  
Carbon Fibre ◽  
Metal Forming ◽  
Carbon Fabric ◽  
Forming Technology ◽  
Joining Technology ◽  
Aluminium Sheets ◽  
Semi Solid ◽  
The University ◽  
The Impact

Das Institut für Umformtechnik (IFU) an der Universität Stuttgart befasst sich derzeit mit der Entwicklung eines neuartigen Verfahrens zum formschlüssigen Fügen von Aluminium- und Carbonstrukturen. Zwei Aluminiumbleche werden dabei lokal auf ein Temperaturniveau knapp oberhalb ihrer Solidustemperatur erwärmt, sodass ein dazwischenliegendes Carbongewebe durch die dann teilflüssige Aluminiummatrix infiltriert werden kann. Dieser Fachartikel befasst sich mit dem Einfluss wichtiger Prozessparameter.   The Institute for Metal Forming Technology (IFU) of the University of Stuttgart aims at the development of a novel joining method for combining aluminium and carbon fibre structures. Two aluminium sheets with carbon fabric in between are conductively heated by two electrodes up to semi-solid state, so the woven carbon fabric is infiltrated with aluminium. This paper focuses on the impact of different process and sample parameters on the quality of the joint.

Synchronized Hydraulic Bulging Forming Technology of Three-Layer-Metal Tubes

2010 ◽  
Vol 143-144 ◽  
pp. 1059-1064
Author(s):  
Wei Wei Wang ◽  
Jian Li Song ◽  
Jing Bo Yu ◽  
B.B. Jia
Keyword(s):  
Numerical Simulation ◽  
Finite Element Analysis ◽  
Theoretical Analysis ◽  
Main Process ◽  
Forming Process ◽  
Element Analysis ◽  
Forming Technology ◽  
Comparison Of The Results ◽  
Hydraulic Bulging ◽  
The Relationship

Synchronized hydraulic bulging forming technology on three-layer-metal tubes was studied. The possibility of three-layer-metal tubes formed by hydraulic bulging method was discussed and proved by elastic-plastic theory. The calculation formulas about the bulging pressure, the residual contact stress and the relationship between them were derived and the main process parameters were analyzed. Finite element analysis was carried out on bulging forming process using MSC. Marc. Practical bulging forming experiments were conducted and well compounded three-layer-metal tubes with tight interfaces were obtained. Through the comparison of the results of theoretical analysis, numerical simulation and practical experiments, proper parameters for the bulging process were obtained and the theoretical analysis was verified and proved.

Novel Direct Coagulation Casting of Alumina Suspensions Using Y3+-Ion Releasing Substances as Coagulant

2014 ◽  
Vol 602-603 ◽  
pp. 164-169
Author(s):  
Yue Dong ◽  
Xiao Dong Li ◽  
Shao Hong Liu ◽  
Ji Guang Li ◽  
Xu Dong Sun
Keyword(s):  
Complex Shape ◽  
High Density ◽  
Green Body ◽  
Alumina Ceramics ◽  
Forming Process ◽  
Coagulation Time ◽  
Near Net Shape ◽  
Net Shape Forming ◽  
Alumina Suspensions

Direct coagulation casting (DCC) is a relatively new ceramic near-net-shape forming process which can form homogeneous ceramic green body with complex shape and high density. Direct coagulation casting of aqueous alumina slurries by adding Y3+ions, which have been frequently used as additive for the sintering of alumina ceramics, were studied. Two different kinds of Y3+-ion releasing substances, Y2O3powder and Y(NO3)3, were used as coagulants and were introduced into stabilized alumina suspensions directly after dispersing. Compared with that of Y2O3powder, both the coagulation time and the added amount required for a reasonable shaping were significantly reduced for using Y(NO3)3as coagulant. The effects of the two coagulants on the properties of the consolidated green bodies and sintered ceramics were studied. The mechanisms of coagulation induced by the addition of Y3+-ions were discussed on the basis of interactions between Y3+ions and the added polyelectrolyte dispersant.

Near Net-Shape Forming of Thermal Barrier Coated Components for Gas Turbine Engine Applications

1998 ◽  
Author(s):  
G.E. Kim ◽  
P.G. Tsantrizos ◽  
S. Grenier ◽  
A. Cavasin ◽  
T. Brzezinski
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Gas Turbine ◽  
Bond Coat ◽  
Gas Turbine Engine ◽  
Thermal Barrier ◽  
Forming Process ◽  
Turbine Engine ◽  
Near Net Shape ◽  
Net Shape Forming

Abstract PyroGenesis Inc. has developed a unique Vacuum Plasma Spraying (VPS) near-net-shape forming process for the production of multilayered free-standing components. Initial evaluation on the feasibility of applying this process for the production of gas turbine engine components has been performed. The VPS near-net-shape forming process consists of: selecting an appropriate mold material; preconditioning of mold surface ; depositing metallic, ceramic, or composite layers ; and removing mold from the spray-formed structure. The near-net-shape components are heat treated to improve their mechanical properties. A suitable heat treatment cycle was developed for the VPS-applied superalloy. Much of the recent improvements in gas turbine engine performance has been attributed to the introduction of thermal barrier coatings (TBC) for superalloy components. There exist, however, some limitations in current fabrication methods for closed hot-section components: less than ideal coating quality; welding; limited choice of superalloy material; etc... PyroGenesis has used VPS near-net-shape forming to fabricate closed components with an yttria-stabilized-zirconia inner layer, CoNiCrA1Y bond coat, and IN-738LC outer layer. The results from the initial study demonstrate the feasibility of producing near-net-shape components with good coating structures, superior superalloy materials, and the absence welds. The mold was reusable after minor surface conditioning. The TBC showed uniform thickness and microstructure with a smooth surface finish. The bond coat and structural superalloy layers were very dense with no signs of oxidation at the interface. After heat treatment, the mechanical properties of the IN-738LC compare favourably to cast materials.

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