Semi Solid Casting and Forging of Steel

Hirt, Gerhard; Bleck, Wolfgang; Bührig–Polaczek, Andreas; Shimahara, Hideki; Püttgen, Wolfgang; Afrath, Carsten

doi:10.4028/www.scientific.net/ssp.116-117.34

Cited by 26 publications

(14 citation statements)

References 23 publications

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“…Consequently, in an attempt to achieve mechanical properties more comparable to that of forging as well as being applicable for high melting point alloys, high solid fractions began to be used with steels in the 1990's [8]. From then on, several authors have assessed the manufacturing of different complex geometries [9,10] and even special alloys were manufactured to enhance the SSP working window and reduce the working temperature [11]. However, they observed premature die degradation, which among others, hindered the possible industrialization [12,13].…”

Section: Introductionmentioning

confidence: 99%

Preliminary Study on the Capability of the Novel Near Solidus Forming (NSF) Technology to Manufacture Complex Steel Components

et al. 2020

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The benefits of the novel Near Solidus Forming (NSF) process has shown previously in its ability to produce steel components with comparable as-forged mechanical properties but with a cost reduction of 10–15%. This study further pushes the NSF technology to produce parts that are conventionally difficult to produce via conventional methods. A 2.7 kg 42CrMo4 steel grade component was manufactured into a complex geometry using only a 400t press. Different manufacturing parameters were evaluated to show their influence on the process and final component. A combination of X-ray fluorescence (XRF), optical microscopy and SEM analysis of the microstructure was also conducted revealing the deformation pattern of the material and shedding some light on how the material evolves during the process. The successful forging of these components shows the capability to produce previously deemed difficult geometries, with much a lower specification forging press, in a single deformation.

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Section: Introductionmentioning

confidence: 99%

Preliminary Study on the Capability of the Novel Near Solidus Forming (NSF) Technology to Manufacture Complex Steel Components

et al. 2020

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“…Advances in casting processing methods have shown additional improvements. For example, the semisolid casting method can be used to produce near net shape parts (Hirt et al 2006).…”

Section: Novel Casting Processesmentioning

confidence: 99%

Advanced Manufacturing and Materials for Hydropower: Challenges and Opportunities

Musa

Ghobrial

Sasthav

et al. 2023

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“…Nevertheless, in 1992 the first investigations about semi-solid forming of steels at high solid content were performed by P. Kapranos et al [7]. Since then, many researchers have tried to manufacture sound components by gaining the advantage of this near-net-shape technique to bring it closer to industry without fortune [8,9]. Gourlay et al studied material behavior at a high solid fraction, typical in NSF processes [10].…”

Section: Introductionmentioning

confidence: 99%

Digital twin development for the sensitivity analysis of near solidus forming process

MUHAMMAD

2023

Materials Research Proceedings

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Abstract. Near Solidus Forming (NSF) process, performed at semi-solid material state is gaining popularity due to its good physical properties, low manufacturing cost and material waste. Although the process possesses many advantages over traditional hot forging, the nature of the process itself is very complex and due to this the researcher struggles to identify the material behavior at NSF conditions. Especially the material model in this condition has not been stated clearly before and therefore it is important to develop a reliable digital twin (DT) strategy which can validate the material model efficiently. Therefore, the objective of this work is to investigate the influence of all DT parameters like billet material and dimensions, billet and dies temperature, heat transfer coefficient, emissivity, ambient temperature, and friction coefficient, in two industrial components such as H spindle and R spindle. The Taguchi Design of Experiments (DOE) approach combined with numerical simulation in FORGE NxT® is employed to develop the sensitivity analysis of the process. The impact of all parameters in the DT are evaluated in terms of die filling and forming forces, and its importance in the material model is studied. Results show that the newly developed approach proposed a novel optimum NSF-DT calibration strategy for material-model validation. Which can be used to develop an accurate model of the NSF process at the laboratory and industrial scale

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Semi Solid Casting and Forging of Steel

Cited by 26 publications

References 23 publications

Preliminary Study on the Capability of the Novel Near Solidus Forming (NSF) Technology to Manufacture Complex Steel Components

Preliminary Study on the Capability of the Novel Near Solidus Forming (NSF) Technology to Manufacture Complex Steel Components

Advanced Manufacturing and Materials for Hydropower: Challenges and Opportunities

Digital twin development for the sensitivity analysis of near solidus forming process

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