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  • 1
    Electronic Resource
    Electronic Resource
    s.l. ; Stafa-Zurich, Switzerland
    Solid state phenomena Vol. 141-143 (July 2008), p. 213-218 
    ISSN: 1662-9779
    Source: Scientific.Net: Materials Science & Technology / Trans Tech Publications Archiv 1984-2008
    Topics: Physics
    Notes: The deformation process of steel in the semi-solid state, or thixoforming is an alternativesolution to the classical industrial processes that are the casting or the hot forging.Thixoformed steel parts are of better quality and may substitute advantageously parts realized incast iron leading to an improvement of the rigidity, for example, but also parts in aluminium alloysobtained by the main deformation processes: for lower volume, thixoformed steel parts, keeping thesame functionality, present superior mechanical properties than the parts realized in aluminiumalloys. The industrial development of the steel thixoforming must be accompanied by theknowledge and the various parameters control of the process: steel grades definition andelaboration, the homogeneous high-temperature heating of the slug before deformation, conceptionor re-conception of the part to adapt it to the process and the practice properties, the equipmentdefinitions which are used for the deformation operation at the semi-solid state. The handlingsystem is also important in the thixoforming process; it is going to allow the slug transfer, at thesemi-solid state, between the heating zone and the tooling or to evacuate the thixoformed parttowards the mean assuring the quality heat treatment of the part. The means choice which areindustrially going to ensure the process have a big importance to obtain successful production lineand so, a cost reduction by “finished” part competitive with regard to processes used classicallytoday. After the description of the applicable key points to the main parameters and the solutionsused to obtain a successful product: high mechanical characteristics, near net shape or net shapegeometry, no flash and limited machining operation, ... are described , The investigations finishedwith an approach comparing the part cost realised by thixoforming process with regard to classicalprocesses
    Type of Medium: Electronic Resource
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  • 2
    Electronic Resource
    Electronic Resource
    s.l. ; Stafa-Zurich, Switzerland
    Solid state phenomena Vol. 141-143 (July 2008), p. 121-126 
    ISSN: 1662-9779
    Source: Scientific.Net: Materials Science & Technology / Trans Tech Publications Archiv 1984-2008
    Topics: Physics
    Notes: Inductive re-heating of billets is the state-of-the-art method to enable the desired liquidfraction for thixoforming. In laboratory experiments the temperature might be directly controlledsince it is usually possible to apply thermocouples for temperature measurements. Due to technicalrestrictions temperature measurements especially in the interior of a billet are difficult in industrialheating processes. For this reason, thixoforming billets are heated without temperature monitoringby using proven heating functions. Such functions are usually obtained by trial-and-error or on thebasis of FEA simulations. In both cases exhaustive experimental work is usually necessary. Moreover,FEA simulations require thermo-physical material data that is difficult to obtain for industrialrelevant heating processes.In this paper an alternative method of experimentally obtaining optimized heating functions by usinga fuzzy logic controller is introduced. Under steady-state environmental conditions this methodallows a quick and reproducible re-heating. The main advantages of the fuzzy logic based approachare that no specific material data is required, system specific properties such as the efficiency havenot be explicitly determined and that the practical implementation could be realized with a minimumof experimental work
    Type of Medium: Electronic Resource
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  • 3
    Electronic Resource
    Electronic Resource
    s.l. ; Stafa-Zurich, Switzerland
    Solid state phenomena Vol. 141-143 (July 2008), p. 207-212 
    ISSN: 1662-9779
    Source: Scientific.Net: Materials Science & Technology / Trans Tech Publications Archiv 1984-2008
    Topics: Physics
    Notes: The development of the thixoforming process made great progress since its beginning.But whereas thixoforming of aluminium and other low melting point alloys is now an industrialreality, thixoforming of high melting point alloys, as steel, is still at the research level. Hightemperature issues, die wearing and production rate are problems that must be solved and are moreand more investigated. This work is a study of the robustness of a complete thixoforming unitdealing with steel. This flexible unit allows parts of various shapes be formed in conditions close toindustrial ones. The study focus on the heating strategy, heat exchanges between the slug and thetool, the feeding and the cycle time. In this work, modelling has been used to simulate heating andfeeding. In parallel, experiments have been made to obtain the needed parameters, to validate themodelling and to evaluate the capacities of such a line
    Type of Medium: Electronic Resource
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  • 4
    Electronic Resource
    Electronic Resource
    s.l. ; Stafa-Zurich, Switzerland
    Solid state phenomena Vol. 141-143 (July 2008), p. 689-694 
    ISSN: 1662-9779
    Source: Scientific.Net: Materials Science & Technology / Trans Tech Publications Archiv 1984-2008
    Topics: Physics
    Notes: The pre and post treatment of the thixoformed parts in terms of heating conditions andcontrolled cooling has a great influence on the final microstructure and the properties of the partsand their homogenization. The paper presents recent investigations on metallographic analysis andhardness measurements on as thixoformed parts and post treated ones. For these tests, different steelgrades are investigated and the liquid fraction of the slug before deformation is evaluated to 30 %
    Type of Medium: Electronic Resource
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  • 5
    Electronic Resource
    Electronic Resource
    s.l. ; Stafa-Zurich, Switzerland
    Solid state phenomena Vol. 141-143 (July 2008), p. 707-712 
    ISSN: 1662-9779
    Source: Scientific.Net: Materials Science & Technology / Trans Tech Publications Archiv 1984-2008
    Topics: Physics
    Notes: Thixoforging is a type of semi-solid metal processing at high solid fraction (0.5〈fs〈1).7075 aluminium alloys have been used as a feedstock for thixoforging in order to investigatethixoformability of a high performance aluminium alloy at high solid fraction. Higher solid fractionof 7075 alloy is less sensitive to temperature, avoids metal splash at high speed and allows laminarflow at high speed. Hot tool combined with lubricant tool coating are used to slow down thesolidification rate of the high solid fraction metal by decreasing thermal exchanges with the tool.Improved thermal and forming parameters [1-2] will be applied to produce an automotivecomponent by thixoforging and mechanical properties have been measured from tensile samples.High mechanical properties are obtained after T6 thermal treatment
    Type of Medium: Electronic Resource
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  • 6
    Electronic Resource
    Electronic Resource
    s.l. ; Stafa-Zurich, Switzerland
    Solid state phenomena Vol. 141-143 (July 2008), p. 719-724 
    ISSN: 1662-9779
    Source: Scientific.Net: Materials Science & Technology / Trans Tech Publications Archiv 1984-2008
    Topics: Physics
    Notes: Thixoforging involves shaping alloys with a globular microstructure in the semi-solidstate. To reach this kind of material, the Recrystallisation and Partial Melting (RAP) process can beused to obtain a globular microstructure from extruded material with liquid penetrating therecrystallised boundaries. Induction heating is used to apply the RAP process to slugs. One of thebenefits of using this method of heating is the fast heating rate (20°C/s). This paper will help toimprove heating parameters by showing their influence on 7075 aluminium alloy recrystallisation.These parameters are the heating rate; heating frequencies-power; presence or not of protective gas;position of the slug in the inductor; energy stored inside the slug; oxide layer on the slug side;chamfer of the slug upper corner
    Type of Medium: Electronic Resource
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  • 7
    Electronic Resource
    Electronic Resource
    s.l. ; Stafa-Zurich, Switzerland
    Solid state phenomena Vol. 141-143 (July 2008), p. 415-420 
    ISSN: 1662-9779
    Source: Scientific.Net: Materials Science & Technology / Trans Tech Publications Archiv 1984-2008
    Topics: Physics
    Notes: Up to now, no technology exists for producing as-cast thixotropic steel at the industrialor pilot level. The existing processes need to reheat a billet that has been previously cast andwrought on separate equipment. The new processing route, we are developing, will allow producingas-cast steel (or high melting point alloy) with thixotropic properties.CRM has developed and patented a continuous casting technology, which by using a speciallydesigned nozzle (HJN nozzle-hollow jet nozzle), allows to combine powder injection and a lowsuperheat. It has been proven by pilot and industrial trials that the combination of iron powderinjection and a low superheat leads to achieve a globular solidification structure in the core of acontinuously cast steel billet. Several industrial trials on continuous caster have been carried outboth with carbon and stainless steel but also on copper in order to modify the solidification structureof these materials.The application of this HJN technology is being studied in order to achieve a globular structure onas-cast steel with the objective to obtain a thixotropic behaviour of the material after an adequatereheating. Casting trials have been performed on CRM continuous casting pilot-line. Specificallydesigned equipment has been built for use in a steel foundry. The influence of the solidification rate,the superheat, the amount and the composition of the powder has been studied
    Type of Medium: Electronic Resource
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  • 8
    Electronic Resource
    Electronic Resource
    s.l. ; Stafa-Zurich, Switzerland
    Solid state phenomena Vol. 116-117 (Oct. 2006), p. 54-57 
    ISSN: 1662-9779
    Source: Scientific.Net: Materials Science & Technology / Trans Tech Publications Archiv 1984-2008
    Topics: Physics
    Notes: This paper focuses on the liquid fraction curves of several steels and the correlationbetween liquid fraction, temperature and heating rate. The work has been performed along two mainaxes. First, the solid fraction versus temperature has been obtained experimentally by differentialscanning calorimetry (DSC), limited to low heating rates. Then, a shift of the liquid fraction curveshas been noticed at high industrial heating rates. The quantification of this effect could not be carriedout by DSC and required the elaboration of another experimental device
    Type of Medium: Electronic Resource
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  • 9
    Electronic Resource
    Electronic Resource
    s.l. ; Stafa-Zurich, Switzerland
    Solid state phenomena Vol. 116-117 (Oct. 2006), p. 618-621 
    ISSN: 1662-9779
    Source: Scientific.Net: Materials Science & Technology / Trans Tech Publications Archiv 1984-2008
    Topics: Physics
    Notes: The behaviour of the semi-solid material is complex to simulate and many approachesare proposed in the literature to represent it. In this work, different constitutive equations arestudied: the classical Northon-Hoff law, Joly and Merhabian’s one [1] and an innovativemicromechanical model using homogenisation technique [2]. These constitutive equations havebeen implemented in the FE code Forge2® to simulate simple forming tests, such as compressionand direct extrusion. The load-displacement curves using the three constitutive equations arecompared in order to estimate their capabilities
    Type of Medium: Electronic Resource
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  • 10
    ISSN: 1662-9779
    Source: Scientific.Net: Materials Science & Technology / Trans Tech Publications Archiv 1984-2008
    Topics: Physics
    Notes: In recent years several attempts were made to transfer the thixoforming technology of steel partsinto industrial applicable processes. This paper gives an overview about the progress of a Europeanconsortium that established a fully automated thixoforming process for the series production ofautomotive steel parts. Due to the multi-faceted nature of this technology, problems concerning thedevelopment of suitable steel grades and tool materials as well as the development and applicationof an inductive heating system, a handling unit and of a complex forming tool had to be solved.Besides the development of adapted steel grades and the inductive heating, the handling of the semisolid billets plays a special role because during the manipulation of the parts from the heating stationinto the tool a loss of heat is unavoidable. Furthermore, scaling of the parts must be prevented.By means of a fully automated process line existing constraints were reduced and the forming processis kept reproducible.Improved silicon nitride composites have been developed as a tool material, which show good mechanicalproperties in combination with an acceptable chemical stability at the occurring processtemperatures as well as in contact with semi solid steel.Basing on the practical experience a comparison of the thixoforming technology to existing processesand an outlook for the future are given
    Type of Medium: Electronic Resource
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