Numerical Simulation on the Die Filling Process of the Thixo-Forging of Al-7 wt pct Si/Al-22 wt pct Si Bimetal Composite

Wang, Guangxu; Huang, H. H.; Yang, Zhao; Shi, Xiaohan; He, Xingyu

doi:10.1007/s11663-015-0404-0

Cited by 5 publications

(5 citation statements)

References 23 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Latent heat of fusion (J kg −1 ), L 4.45 × 10 5 [31] Thermal conductivity of the mould (Wm −1 K −1 ), k 1.4 [32] 19.54 [33,34] Density of the mould (kg m −3 ), ρ 1570 [32] 7800 [33,34] Specific heat of the mould (J kg −1 K −1 ), C 1153 [32] 522 [33,34] Density of the metal (kg m −3 ), ρ m 2.76 × 10 3 [35] Specific heat of the metal (J kg −1 K −1 ), C m 1058 [36]…”

Section: Sand Mould Metallic Mouldmentioning

confidence: 99%

A Novel Approach of Optimum Time Interval Estimation for Al-7.5Si/Al-18Si Liquid–Liquid Bimetal Casting in Sand and Metallic Moulds

et al. 2023

View full text Add to dashboard Cite

This work describes a novel approach for Al-7.5Si/Al-18Si liquid–liquid bimetal casting in sand and metallic moulds. The aim of the work is to facilitate and develop a simple procedure to produce an Al-7.5Si/Al-18Si bimetallic material with a smooth gradient interface structure. The procedure involves the theoretical calculation of total solidification time (TST) of the first liquid metal (M1), pouring the liquid metal (M1), and allowing it to solidify; then, before complete solidification, the second liquid metal (M2) is introduced into the mould. This novel approach has been proven to produce Al-7.5Si/Al-18Si bimetal materials using liquid–liquid casting. The optimum time interval of Al-7.5Si/Al-18Si bimetal casting with modulus of cast Mc ≤ 1 was estimated based on subtracting 5–15 s or 1–5 s from TST of M1 for sand and metallic moulds, respectively. Future work will involve determining the appropriate time interval range for castings having modulus ≥ 1 using the current approach.

show abstract

Section: Sand Mould Metallic Mouldmentioning

confidence: 99%

A Novel Approach of Optimum Time Interval Estimation for Al-7.5Si/Al-18Si Liquid–Liquid Bimetal Casting in Sand and Metallic Moulds

et al. 2023

View full text Add to dashboard Cite

show abstract

“…Bimetallic materials fabricated though liquid-solid and liquid-liquid casting routes could be promising alternatives for metal and polymer matrix composites for a wide range of materials to be used for engineering applications due to their low cost and high gradient physical and mechanical properties (Ramadan et al, 2020a, b and c). Researchers are applying extensive effort in order to control the composition and microstructure across the components to design materials with graded properties (Parihar et al, 2018, andWang et al, 2015). For lightweight, tough, wear-resistant and low-cost FGM, designers are working on composite structures composed of dissimilar materials (Zhao et al, 2019;Wróbel, 2011).…”

Section: Introductionmentioning

confidence: 99%

“…Researchers are applying extensive effort in order to control the composition and microstructure across the components to design materials with graded properties (Parihar et al, 2018, andWang et al, 2015). For lightweight, tough, wear-resistant and low-cost FGM, designers are working on composite structures composed of dissimilar materials (Zhao et al, 2019;Wróbel, 2011). The notable merit of such dissimilar alloys is that a smooth change in properties can be achieved by combining different constituent alloys together, such as 304 stainless steel surface layer and a cast iron base by Ramadan (2015), and Ramadan et al (2017), two different Al-Si alloys by Scanlan et al (2005), a Babbitt-steel bimetal composite by Fathy et al (2018) and an Al/Mg alloy by Li et al (2019), Z.…”

Section: Introductionmentioning

confidence: 99%

Interfacial microstructures and properties of hyper-eutectic Al–21Si / hypo-eutectic Al–7.5Si bimetallic material fabricated by liquid–liquid casting route

Ramadan

Alghamdi

2020

Mech. Sci.

View full text Add to dashboard Cite

Abstract. The bimetal casting process using the liquid–liquid technique was developed to produce a high-quality hyper-eutectic Al–21Si / hypo-eutectic Al–7.5Si alloy bimetal material. Microstructure and microhardness were investigated as a function of the time interval between pouring hypo-eutectic and hyper-eutectic alloys. A bimetal material was successfully fabricated using a liquid–liquid casting technique with a 10 s time interval in a permanent mould casting. A unique structure comprised of hyper-eutectic Al–21Si, hypo-eutectic Al–7.5Si and a eutectic interface of 70 µm thickness was obtained. This structure totally differs from that obtained using a higher time interval above 10 s that showed an imperfect interface bond due to the shrinkage cavity and formation of oxides. The hardness variation from the upper zone of 117.5 HV to the lower zone of 76 HV corresponded to the variation in Si and the content of other alloying elements. The proposed total solidification time control method is a promising approach for the successful fabrication of liquid–liquid bimetal material.

show abstract

“…Semi-solid metal forming process is a good near net forming technology, and is applied on automotive industry, aerospace industry, et al [1][2][3][4]. In our previous research, thixo-forging has been proved to be able to manufacture bi-metal products with complex shape economically [5][6][7]. The good formability of semisolid billets ensured the good size precision and the good die filling character.…”

Section: Introductionmentioning

confidence: 99%

“…Because the semisolid billets cannot transfer the forging force efficiently, variation of the shape of the interface usually occurred when the states of the billets and the outline of the cavity are different. Even though, the interface is still controllable [7].…”

Section: Introductionmentioning

confidence: 99%

Macro-Observation of the Interface of the Al-22%Si-Cu/Al-7%Si-MG Bi-Metal Parts Fabricated by Thixoforging

Yang

Wang

et al. 2016

SSP

View full text Add to dashboard Cite

Thixo-forging has been proved to be able to fabricate bi-metal parts with a complex outline and a relatively regular interface economically. These products have potential applications on high volume stability radiators, brakes, and pistons. However, it is very difficult to evaluate the curved interfaces by micro observations. In this work, Al-22%Si-Cu/Al-7%Si-Mg bi-metal parts were fabricated by thixo-forging; state of the interfaces of the bi-metal parts was investigated by X-ray flaw detector observations and tensile test; optical microscope (OM) observation and scan electron microscope (SEM) observation were applied to assist the analysis. The results show that the metallurgical bonding of the interfaces is of good quality. No large scale flaw was found on the interface in X-ray flaw detector observation. It was found that higher forging pressure decreased the size of the crack on the interface and in the matrix. However, higher forging pressure can slightly improve tensile strength. Large ratio of fresh interface relates to original interface resulted in a slightly better tensile strength. Without heat-treatment, the bi-metal forgings have an average tensile strength of 106 MPa. T6 heat treatment blunted the blades of the plate like crack and nodulized the defects, T6 heat treatment also decreased the size of the Si particles. As a result, the average tensile strength of the bi-metal forgings increased to 200 MPa.

show abstract

Numerical Simulation on the Die Filling Process of the Thixo-Forging of Al-7 wt pct Si/Al-22 wt pct Si Bimetal Composite

Cited by 5 publications

References 23 publications

A Novel Approach of Optimum Time Interval Estimation for Al-7.5Si/Al-18Si Liquid–Liquid Bimetal Casting in Sand and Metallic Moulds

A Novel Approach of Optimum Time Interval Estimation for Al-7.5Si/Al-18Si Liquid–Liquid Bimetal Casting in Sand and Metallic Moulds

Interfacial microstructures and properties of hyper-eutectic Al–21Si / hypo-eutectic Al–7.5Si bimetallic material fabricated by liquid–liquid casting route

Macro-Observation of the Interface of the Al-22%Si-Cu/Al-7%Si-MG Bi-Metal Parts Fabricated by Thixoforging

Contact Info

Product

Resources

About