Simplified Rheocasting of Al-Si Alloys Sheared by Mechanical Stirring

2015 ◽  
Vol 651-653 ◽  
pp. 1545-1550 ◽  
Author(s):  
Alfredo Hernández ◽  
J. Federico Chávez ◽  
Raquel E. Hernández
Keyword(s):  
Stainless Steel ◽  
Solid State ◽  
Shear Rate ◽  
Microstructural Characterization ◽  
Dendritic Morphology ◽  
Solid Alloy ◽  
Mechanical Stirring ◽  
Simplified Method ◽  
Thixotropic Behavior ◽  
Semi Solid

A rheocasting prototype for the semi-solid processing of Al-Si alloys was designed and assembled at laboratory scale, this is the first attempt for the development of S2P equipment in Mexico. This work describes the simplified method of mechanical stirring and the calculation of the theoretical parameters for the operation of the experimental device in order to provide shear rate into the slurry by a stainless steel impeller inside a crucible made of hot work steel. Moreover, a vertical pressure die-rheocasting system it is applied with the semi-solid alloy flowing counter the position of the injector during the displacement of the crucible in order to fill the mold. New design is applied in this rheocasting equipment.The semi-solid state with thixotropic behavior is produced in the stirred AlSi7Mg alloy; this condition allows the non-dendritic morphology because the intensively stirring at the beginning of the solidification produces the trimming of dendrites, growing so the primary solid (α) in globular shape surrounded by eutectic microstructure. Preliminary microstructural characterization was performed.

Evaluation of Strip Rolling Directly from the Semi-Solid State

2006 ◽  
Vol 116-117 ◽  
pp. 433-436 ◽  
Author(s):  
Antonio de Pádua Lima Filho ◽  
Márcio Iuji Yamasaki
Keyword(s):  
Solid State ◽  
Cooling System ◽  
Solid Alloy ◽  
Strip Rolling ◽  
Tin Alloys ◽  
Cooling Slope ◽  
Quality Issue ◽  
Lower Roller ◽  
Semi Solid ◽  
Strip Quality

The aim of this work is to study the solidification conditions necessary to produce good quality/low defect metal alloy strip when thixorolling directly from the semi-solid state. To facilitate the study lead/tin alloys were chosen for their relatively low operating temperature. The objective is to extrapolate these findings to the higher temperature aluminium alloys. Three alloys (70%Pb- 30%Sn, 60%Pb-40%Sn, 50%Pb-50%wtSn) were used particularly to study the influence of the solidification interval. The equipment consists of a two roll mill arranged as an upper and lower roller, where both rollers are driven at a controlled speed. The lower roller is fed with semi solid alloy through a ceramic nozzle attached to the lower end of a cooling slope. Several types of nozzle and their position at the roller were tested. This produced different solidifications and consequently different finished strip. The alloys were first cast and then poured onto the cooling slope through a tundish in order to create a continuous laminar flow of slurry and uniformity of metal strip quality. The pouring was tested at different positions along the slope. The cooling slope was coated with colloidal graphite to promote a smooth slurry flow and avoid the problem of adherence and premature solidification. The metallic slurry not only cools along the slope but is also initially super-cooled to a mush by the lower roller whilst at room temperatures, thus enabling thixorolling. It was also found that the nozzle position could be adjusted to enable the upper roller to also contribute to the solidification of the metallic slurry. However the rollers and the cooling slope naturally heat up. Temperature distribution in these zones was analysed by means of three thermocouples positioned along the cooling slope and a fourth in the base of the semi solid pool within the nozzle. The objective being to design an optimum pouring and cooling system. The formed strip was cooled down to room temperature with a shower of water. Microstructures of the thixorolling process were analysed. The differences in solidification conditions resulted in differing qualities of finished strip and corresponding defect types, all of which are a serious quality issue for the rolled product.

Microstructure and Mechanical Properties of Sn-Bi Alloy Treated in the Semi-Solid State by Mechanical Stirring Process

2010 ◽  
Vol 150-151 ◽  
pp. 1768-1771 ◽  
Author(s):  
Feng Li ◽  
Yong Jun Hu ◽  
Xiao Ling Cheng ◽  
Xiao Ting Xiao
Keyword(s):  
Mechanical Properties ◽  
Solid State ◽  
Die Casting ◽  
Percentage Elongation ◽  
Mechanical Stirring ◽  
Microstructure And Mechanical Properties ◽  
Stirring Time ◽  
Microstructures And Mechanical Properties ◽  
Semi Solid

In this work, the effect of stirring time on the solidifed microstructures and mechanical properties of semi-solid Sn-Bi slurry was investigated by the mechanical stirring method. The results indicated that a fine round granular solidifed structure of Sn-Bi semi-solid slurry was obtained at 142 and stirred for 8 min. Compared with the Sn-Bi alloy prepared conventional die casting, the mechamical properties of semi-solid Sn-Bi alloy was improved prominently. The percentage elongation of semi-solid Sn-Bi alloy was increased 67 % compared with that of the Sn-Bi alloy prepared conventional die casting.

Influence of Morphology on the Rheological Behavior of Semi-Solid A356 Aluminum Alloy

2006 ◽  
Vol 116-117 ◽  
pp. 601-605
Author(s):  
Heng Hua Zhang ◽  
Xian Nian Zhang ◽  
Guang Jie Shao ◽  
Luo Ping Xu ◽  
Yi Tao Yang ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Solid State ◽  
Rheological Behavior ◽  
Apparent Viscosity ◽  
Flow Behavior ◽  
A356 Alloy ◽  
Solid Alloy ◽  
A356 Aluminum Alloy ◽  
A356 Aluminum ◽  
Semi Solid

The morphology of semi-solid alloy is one of the key influence factors on the rheological behavior of slurry during die filling and the mechanical properties of formed parts. However, it is difficult to study such effect due to hard controlling of morphology in semi-solid state. In this paper, a self-developed Searle-type viscometer was used to determine the rheological behavior of A356 aluminum alloy in different morphology, which was refined with the salts mixture of K2TiF6 and KBF4. The results indicated that the flow behavior of refined A356 alloy in the semi-solid state possesses obviously thixotropic behavior under isothermal shearing condition with less time to reach steady state and lower steady apparent viscosity as compared to that of the A356 alloy. During continuous cooling at a constant shearing rate, the apparent viscosity of refined A356 slurry in the same solid fraction decreased with the content of Ti. It is shown from quantitative image analysis that the primary α-Al grain in the refined alloy evolves from dendrites to rosettes or sphericitys, and then tends to be rounder and finer in higher Ti content. The mechanism of the influence of morphology on rheological behavior was also discussed in this paper.

Effect of Disturbing Conditions in Semi-Solid State on Microstructure Evolution of Magnesium Alloy

2006 ◽  
Vol 116-117 ◽  
pp. 296-299 ◽  
Author(s):  
Hong Jin Zhao ◽  
Yong Lin Kang ◽  
Zhao Hui Wang ◽  
Hai Liang Du
Keyword(s):  
Solid State ◽  
Magnesium Alloy ◽  
Microstructure Evolution ◽  
High Efficiency ◽  
External Disturbance ◽  
Dendritic Structure ◽  
Good Effect ◽  
Mechanical Stirring ◽  
Β Phase ◽  
Semi Solid

In this paper the microstructure evolution of AZ91HP magnesium alloy casts produced under different disturbing treatment conditions such as non-disturbing, argon blowing and mechanical stirring in semi-solid state after holding a short time was studied. The results show that the grains of AZ91HP alloy casts refined, the secondary dendritic arms grown and the dendrites tend to rosette shape with the decrease of holding temperature. External disturbance can accelerate the evolution process, and the spherical primary α phase formed easily under mechanical stirring treatment condition. The formation of non-dendritic structure is owing to ripening of the dendritic arms, refinement of the grains and movement of the primary formed solid phases. Disturbing treatments in semi-solid state induce more equilibrium solidification and decrease the amount of brittle β-Mg17Al12 phase. Blowing argon into the refined and modified magnesium alloy in semi-solid state can obtain homogeneous non-dendritic structure and the net shaped β phase distributed on α-Mg phase boundaries become fine and thin, this may be have a good effect on the mechanical properties of the magnesium alloy casts. Due to the low disturbing strength, argon blowing can maintain the metallurgy quality of the semi-solid slurry well, and also have high efficiency to make it. This technology need not new complex equipments and can be practiced in conventional casting conditions, so it may be used in industrialize manufacture.

Thixotropic Strength and Thixotropic Criteria in Semi-Solid Processing

2008 ◽  
Vol 141-143 ◽  
pp. 319-323 ◽  
Author(s):  
W.C. Keung ◽  
Y.F. Lee ◽  
Wei Wei Shan ◽  
Shou Jing Luo
Keyword(s):  
Shear Stress ◽  
Shear Rate ◽  
Shape Factor ◽  
Shear Thickening ◽  
Solid Material ◽  
Solid Content ◽  
Solid Particles ◽  
Thixotropic Behavior ◽  
Semi Solid ◽  
Constant Shear Rate

Thixotropy is essential to semi-solid processing, and because of it the semi-solid material is characterized by ‘shear shinning’. Here, thixotropic strength and thixotropic criteria in semi-solid processing are put forward based on related theories and experiments, and thixotropic mechanism and its influencing factors are also investigated. The results are as follows: 1) the term of thixotropic strength means that with constant shear rate at semi-solid temperature, the semi-solid body begins to flow when the shear stress reach a certain value. This value of shear stress is defined as the thixotropic strength; 2) Thixotropic behavior happens with ‘shear thinning’ because of the deagglomeration of solid particles, while ‘shear thickening’ happens because of the agglomeration at the same time. With increasing shear time, the shear stress increases first and then decreases rapidly to reach a stable value. 3) There are three important factors that influence ‘thixotropic strength’: temperature (hence solid content), initial microstructure (including size, shape factor and uniformity of solid particles) and shear rate.

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.

Modelling of Extrusion Process for Aluminium A356 Alloy

2014 ◽  
Vol 217-218 ◽  
pp. 188-194 ◽  
Author(s):  
Sudip Simlandi ◽  
Nilkanta Barman ◽  
Himadri Chattaopadhyay
Keyword(s):  
Shear Stress ◽  
Solid State ◽  
Numerical Solutions ◽  
Energy Requirement ◽  
A356 Alloy ◽  
Extrusion Process ◽  
Solid Alloy ◽  
Governing Equations ◽  
Semisolid Alloy ◽  
Semi Solid

In the present work, a model is developed to study extrusion process of A356 alloy in semi-solid state. The distinct rheology of the semisolid alloy reduces energy necessity during extrusion process. Accordingly, a proper rheological model of the alloy is considered in the model towards a detailed study of the process. A combination of analytical and numerical solutions is considered for solving the governing equations. The work finally predicts distribution of velocity and shear stress of the alloy under shear in the considered domain. It also predicts the energy requirement during the extrusion process. It is demonstrated that for semisolid extrusion, reasonably less energy is required as compared to a conventional extrusion process Keywords: Extrusion, semi-solid alloy, apparent viscosity, extrusion power

Thixotropic Behavior of Semi-Solid Magnesium Alloy

2006 ◽  
Vol 116-117 ◽  
pp. 648-651 ◽  
Author(s):  
Hsueh I Chen ◽  
Jyh Chen Chen
Keyword(s):  
Shear Stress ◽  
High Temperature ◽  
Magnesium Alloy ◽  
Shear Rate ◽  
Experiment Data ◽  
Az91d Magnesium Alloy ◽  
Thixotropic Behavior ◽  
Semi Solid ◽  
Rising Time ◽  
Shear Thinning Fluid

By a high-temperature Couette type viscometer, we studied the thixotropic behavior of the semi-solid AZ91D magnesium alloy slurry. According to different variable conditions, we could measure the change of the shear stress. The results showed that the shear stress of semi-solid AZ91D magnesium alloy slurry increased at starting shearing, and the shear stress fell down at the maintained shear rate shearing. In our experiment data, we found that the semi-solid AZ91D magnesium alloy slurry had the behavior of shear thinning fluid. As the maximum shear rate increased, the measured shear stress increased at a dissimilar level. When the rising time was shorter, the increasing range of shear stress was larger. As the shearing time of the maintained shear rate increased, the falling down degree of the shear stress increased and it can be presented as a function of shearing time, such as: e 0.0159t min 11331 τ = − . At the same shear rate, the area of hysteresis loop was bigger and the thixotropic behavior was more obvious.

Study on Semi-Solid Magnesium Alloy Produced by Mechanical Stirring

2010 ◽  
Vol 146-147 ◽  
pp. 1723-1728
Author(s):  
Bing Feng Zhou ◽  
Hong Yan
Keyword(s):  
Magnesium Alloy ◽  
Cooling Rate ◽  
Dendritic Structure ◽  
Spherical Particles ◽  
Solid Alloy ◽  
Mechanical Stirring ◽  
Stirring Rate ◽  
Stirring Time ◽  
Semi Solid ◽  
Spherical Grains

Semi-solid magnesium alloy slurry was produced by a newly self-developed mechanical stirring machine in order to prepare continuous semi-solid slurry. The changing principle of semi-solid microstructure was studied under different conditions—the changing of temperature, stirring rate, cooling rate and stirring time. It was showed that the lower the temperature of slurry, the higher the stirring rate, the longer the stirring time and the faster the cooling rate, the grain will be smaller and more evenly rounded. When the stirring speed and temperature are the same, better semi-solid spherical grains can be gained by increasing the stirring time. At the same stirring temperature and higher stirring speed, semi-solid spherical particles are smaller, rounder and more evenly; at a low stirring speed, we can't get ideal semi-solid spherical grains even if we increase the stirring time. The ideal technological parameters of semi-solid AZ61 alloy produced with no-dendritic structure were recommended to be 600°C～605°C (stirring end temperature) 、3min～ 5min(stirring time) and 500r/min(stirring rate). Compared with conventional casting alloy, semi-solid alloy mechanical properties were greatly improved. The non-dendrite semi-solid forming mechanism was studied; mechanical stirring semi-solid non-dendritic formation was the result of a variety of factors, the key cause is mechanical shear stress.

Sign in / Sign up

Export Citation Format

Share Document