The effect of injection conditions on the structural integrity of the components produced by semi-solid Rheocasting

Abstract

This work is a contribution to improve understanding about the behaviour of components produced by semi-solid processes. The present study shows the effect of different conformation parameters on automotive cranking cover production obtained by Semi-Solid Rheocasting Process (SSR®). The components were produced using EN AC-46500 alloy, by an industrial plant with a 700 Ton HPDC machine and an IDRA SSR Station.The process parameters studied were slurry temperature, agitation time, speed injection and lubrication system. The characterization was carried out by microstructural analysis, X-rays and mechanical tests. The components show good mechanical properties, similar to those obtained by die cast. The process was simulated using the PROCAST program.

New mechanical stirring system to study the rheological behaviour of semisolid A380 second melting aluminium alloy

“…The technique of PMSM starts from the concept of the mechanical stirring process [19,20] and consists to obtain a globular microstructure trough mechanical agitation and solidi cation control. The differences with others mechanical stirring processes are the control of the viscosity instead of time and refrigeration system of the implemented bar.…”

A Comparison of Microstructure and Casting Defects of Rheocasting and Thixocasting Al-Si-Mg Alloy

“…Although several different rheocasting processes have been developed (i.e. new rheocasting process (NRC) [2], sub-liquidus casting process (SLC) [3], semisolid rheocasting process (SSR) [4], gasinduced superheated-slurry process (GISS) [5], swirling enthalpy equilibration device process (SEED) [6]), rapid-S or the rheoMetal process [7]), maintaining the cleanliness of the metal in rheocasting is still challenging. In contrast, although thixocasting is costlier than rheocasting, thixocasting can produce the components with excellent functional and mechanical properties.…”

A Comparison Between Semisolid Casting Methods for Aluminium Alloys

“…Driven by the needs to produce high quality, lower costs parts for primarily the electronics and automotive industries, several different rheocasting processes have been developed. Examples of these processes are the New Rheocasting process (NRC) [4,5], Sub-Liquidus Casting process (SLC) [6,7], Semisolid Rheo Casting process (SSR) [8][9][10], rheo-die casting [7], Gas-Induced Superheated-Slurry process (GISS) s [11], Rapid-S or the RheoMetal process [8], Swirling Enthalpy Equilibration Device process (SEED) [12][13][14][15][16][17][18] and many more. The leading processes with the strongest industrialisation are the GISS, RheoMetal and SEED processes [3].…”