Production of Aluminium Based Interpenetrating Phase Composites Using Semi-Solid Forming

2016 ◽  
Vol 716 ◽  
pp. 502-509 ◽  
Author(s):  
Christoph Seyboldt ◽  
Mathias Liewald ◽  
Daniel Heydt
Keyword(s):  
Liquid Phase ◽  
Aluminium Alloy ◽  
Ceramic Materials ◽  
Raw Material ◽  
Phase Fraction ◽  
Forming Process ◽  
Ceramic Foams ◽  
Forming Technology ◽  
Semi Solid ◽  
Interpenetrating Phase Composites

The following paper deals with the production of Interpenetrating Phase Composites (IPC) using semi-solid forming technology. Therefore, adequate ceramic foams were selected and infiltrated by processing the aluminium alloy A356 in the semi-solid state. In the studies presented in this paper, the infiltrations of two ceramic materials (Al2O3 and SiC) with three different pore sizes (10, 20 and 30 ppi) were investigated. During the forming process the liquid phase fraction of the aluminium was varied to analyze infiltration effects in relation to the raw material´s liquid phase fraction. Afterwards, microsections of the produced specimens were analyzed in order to characterize their microstructure and the quality of infiltration. The results showed that completely filled composite components with good mechanical properties can be produced by infiltrating ceramic preforms with a semi-solid aluminium alloy.

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.

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.

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.

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.

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.

An Experimental Investigation on Semi-Solid Forming of Micro/Meso-Scale Features

2006 ◽  
Vol 129 (2) ◽  
pp. 246-251 ◽  
Author(s):  
Gap-Yong Kim ◽  
Jun Ni ◽  
Rhett Mayor ◽  
Heesool Kim
Keyword(s):  
Material Flow ◽  
Optical Measurement ◽  
Solid Material ◽  
Complex Interaction ◽  
Experimental Setup ◽  
Forming Process ◽  
Die Filling ◽  
Forming Technology ◽  
Semi Solid ◽  
Meso Scale

The potentials of semi-solid forming technology have generated much interest regarding its application in micromanufacturing. This study investigates the feasibility of using semi-solid forming technology to produce parts with micro/meso features. An experimental setup has been developed to study the effects of die/punch temperature, initial solid fraction, punch speed, and workpiece shape on the semi-solid forming process. A part has been produced for a microreactor application and has been analyzed with an optical measurement system for feature formation. The results indicated complex interaction among the process parameters and the material flow, which affected the final pin formation. The punch temperature and velocity had a significant effect on the overall die filling. The initial workpiece shape and solidification of the semi-solid material during forming influenced the micro/meso-feature formation sequence, affecting the final pin formation. Furthermore, grain deformation and distribution of the formed parts were investigated. The grains became larger due to induction heating and the forming process. Severely distorted grains were observed at the corner regions of the pins and the punch-workpiece interface.

Production of Titanium Alloy Components by Semi-Solid Forming

2012 ◽  
Vol 192-193 ◽  
pp. 515-520 ◽  
Author(s):  
Levente Kertesz ◽  
Mathias Liewald
Keyword(s):  
Mechanical Properties ◽  
Metal Forming ◽  
Medical Engineering ◽  
High Variability ◽  
Development Work ◽  
Forming Process ◽  
Forming Technology ◽  
Semi Solid ◽  
New Research ◽  
The University

The relatively high costs of processing titanium alloys and the high variability in the products' quality currently represent the major economic obstacles to using such materials in either production or medical engineering. For this reason, new research and development work at the Institute for Metal Forming Technology of the University of Stuttgart is pursuing the objective of improving and enhancing pre-existing processes for these types of materials. In doing this, aspects are considered which specify definite mechanical properties during and after the forming process as well as reduce the costs by means of cutting the manufacturing times, increase the use of semi-finished products and minimise finishing operations.

The Microstructure Evolvement and Simulation Analysis during Semi-Solid Processing of Aluminum Alloy

2008 ◽  
Vol 141-143 ◽  
pp. 139-144 ◽  
Author(s):  
Yi Tao Yang ◽  
Jian Fu Wang ◽  
Heng Hua Zhang ◽  
Guang Jie Shao
Keyword(s):  
Liquid Phase ◽  
Solid Phase ◽  
General Structure ◽  
Die Casting ◽  
Fluid Velocity ◽  
Solid Particles ◽  
Forming Process ◽  
Unequal Distribution ◽  
Semi Solid ◽  
Die Castings

To enhance the comprehension on the internal rule of microstructure evolvement and quality-controlled relativity, the microstructure during the induction reheating of billets and die casting of parts was systematically investigated. According to general structure observation and aided analysis of some computer simulations, the quantitative relationships between microscopic morphology (including solid fraction and grain shape) and formation state was minutely discussed. The experimental results showed that liquid and solid phase in semi-solid slurry had different filling tendency, fluid velocity of liquid phase in the area of high filling speed was relative quick and easy to flow into far area and corner. Solid particles far from gate possessed fine and round grain. Moreover, the structure configuration of original billets markedly affected forming process; billets with fine and round grain were required for the die-castings of complex shape and thin thickness. In the case of the big change in shape and thickness of die-castings, the design of gating system and the control of plunger speed should be so properly carried out as to avoid unequal distribution of solid and liquid phase in die-casting part as soon as possible.

Basic Investigations on Joining of Metal and Fibre Components Based on the Semi-Solid Forming Process

2015 ◽  
Vol 651-653 ◽  
pp. 1445-1450 ◽  
Author(s):  
Lukas Marx ◽  
Mathias Liewald ◽  
Kim Rouven Riedmüller
Keyword(s):  
Research Work ◽  
Textile Fibre ◽  
Forming Process ◽  
Forming Technology ◽  
New Material ◽  
New Type ◽  
Semi Solid ◽  
Cleaning Methods ◽  
Joining Process ◽  
Adhesive Materials

The trend towards lightweight construction in automotive engineering causes additional effort and higher expense in vehicle manufacturing, because new materials or, respectively, new material combinations require adapted production and processing methods. Various combinations of metallic and fibre-based structures (GRP-/ CFRP components) presuppose convenient joining methods. In this context, an innovative joining method for combining sheet metals with carbon textiles is going to be developed at the Institute for Metal Forming Technology (IFU, University of Stuttgart / Germany). The goal of this research work is motivated by the prevention of any damage of the used textile fibre structures during the joining process (compared to mechanical joining methods like screwing or riveting). Based on the semi-solid forming technology, the new joining process is going to be developed to create a material integrated interlock between fibres and metallic components.This paper deals with the first fundamental investigations, conducted at IFU, which have already shown the technical feasibility of this new type of joining technique. The research work to be carried out comprises the usage of different sheet alloys: the combinations steel-aluminium, aluminium-aluminium and steel-steel are to be joined with layers of carbon fibre fabrics. By this innovative joining method, a firmly bonded and non-aging connection between textile and metallic materials is to be produced, without the need of any adhesive materials or associated preparative cleaning methods.

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