Semi-solid Metal (SSM) Processing A New Approach to Metal Casting

By Dr. Muhammad Kamran

Introduction
Discovered at MIT

in 1971 During study of hot tearing of steel during solidification Modeled by Sn-15Pb alloy using Coeutte Rheometer

Semi-solid Metal Processing

Non-dendritic structure Solid-liquid region Suitable fraction solid

Property exploited is

Rheology

Steady state rheology (Rheology) Transient state rheology (Pseudoplasticity) Time dependent rheology (Thixotropy)
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Evolution to Non-dendritic Microstructure

Under Forced Convection Fragmentation of primary dendrites by Root melting of secondary dendritic arms Bending and shearing of secondary denritic arms Bending and root melting of secondary arms Fragments of primary dendrites grow into globular grains under forced convection
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Evolution to Non-dendritic Microstructure

Partial melting and Iso-thermal

holding

Low temperature eutectic phase melts in semi-solid range Highly stressed grain boundaries favours wetting of grains with liquid Grain become globular to reduce curvature and liquidsolid interface energy

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Semi-solid Metal processing by Dr. Muhammad Kamran

Introduction
Characteristics of Slurry

Sheared semi-solid slurry shows apparent viscosity similar to machine oil

SSM Processing exploits
T Conventional solidification Semi-solid Processing Liquid + Solid

Solidification mechanism in the solid-liquid range i.e. nucleation and growth mechanisms
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Liquid

Solid

Semi-solid Metal processing by Dr. Muhammad Kamran

Composition, Time

Alloy Characteristics
Solidification range Low melting point

phase/eutectic phase Temperature Sensitivity of solid fraction Castability Potential for aging etc.

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Semi-solid Metal processing by Dr. Muhammad Kamran

Fraction Solid Processing Range Temperature 6

Introduction
Classification suggested by Flemings et.Al. Rheocasting Shearing the liquid while cooling from liquid to liquid solid range and casting a net-shape product Thixocasting Shearing a partially melted suitable precursor in semisolid range Compocasting Shearing a miscible or immiscible mixture of composite in the solid-liquid range

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Semi-solid Metal processing by Dr. Muhammad Kamran

Evolution to Non-dendritic Microstructure

Other Mechanisms

Grain refinement Spray forming and sintering Ultrasonic vibrations etc.

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Semi-solid Metal processing by Dr. Muhammad Kamran

Processing Techniques
Techniques for feed stock

Techniques for Finished Product

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Semi-solid Metal processing by Dr. Muhammad Kamran

Semi-solid Metal Processing Techniques

Techniques for non-dendritic Feedstock

Mechanical Stirring Megnatohydrodynamic (MHD) Stirring Stress Induced and melt Activated (SIMA) Process Spray Forming Liquidus Casting Ultrasonic treatment Grain refienment etc.
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Semi-solid Metal Processing Techniques

Mechanical Stirring Developed at MIT Stirring of liquid alloy while controlled cooling in the semisolid range using auger, impeller or paddle Batch type or continuous process For Rheocasting and Thixocasting
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Semi-solid Metal Processing Techniques

Magnetohydrodynamic (MHD) Stirring

Patented by Alumax Inc. Vigorous stirring by rotating magnetic field within the mould Normally for producing feedstock for thixocasting Disintegrated fine dendrites which convert to globular grains on partial melting

Most widely used process

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Semi-solid Metal Processing Techniques

Stress Induced and Melt Activated (SIMA) Process Severe deformation of precursor results in residual stresses On heating recrystallisation occurs On partial melting low melting point phase becomes liquid High residual stress favours wetting of grain boundaries Higher curvature and liquid-solid interface energy favours globular grain morphology

Longer holding time favours coarsening and agglomeration which deteriorate semisolidprocessability
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Semi-solid Metal Processing Techniques

Liquidus Casting Pouring of melt at near-liqudus temperature Higher rate of Nucleation favouring fine grain size

On partial melting fine grains transform to globular grains

Grain Refinement Promote heterogeneous nucleation

Finer grain size

Grains transform to globular on partial melting
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Semi-solid Metal Processing Techniques

Techniques for Net-shape Product

Rheocasting Thixoforming Thixomoulding Rheomoulding etc.

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Semi-solid Metal Processing Techniques

Rheocasting

Non-dendritic ally slurry obtained from shearing while cooling from liquid state Mechanical stirring MHD Stirring New Rheocasting (NRC)

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Semi-solid Metal Processing Techniques

Thixocasting Partial melting of suitable feedstock

Mechanical stirring MHD stirring SIMA process Spray forming

Thixocasting Thixoforging
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Semi-solid Metal Processing Techniques

Thixomoulding Simultaneous heating and shearing of solid feedstock in a chamber by rotating barrel Designed for Mg alloy Controlled atmosphere Similar to injection moulding

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Semi-solid Metal Processing Techniques

Rheomoulding

Vigorous Shearing of liquid alloy using screw type drive while cooling Similar to Injection moulding Suitable even for immiscible alloy formation and processing

Twin Screw Rheomoulding (TSRM) process is an upgradation

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Commercial features

Advantages

Energy efficient Production rate compete that for pressure die casting Smooth die filling with no air entrapment favouring product soundness Lower processing temperature Lower Impact to the die Reduced solidification shrinkage
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Commercial features

Disadvantages

Relatively higher feedstock material cost Precise control of operating condition is required. Liquid segregation may occur as a result of non-uniform heating

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Commercial features
Potential Applications Replacement of permanent mould parts to eliminate machining and finishing Pressure tight parts such as master brake cylinders, fuel rails, air conditioner compressor housing etc. High strength parts such as engine mounts, tie rods etc. Wear resistant parts made from hypereutectic alloys such as compressor piston, brake drums, gear shift levers etc. Forged parts requiring excessive tooling

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Commercial features
Current Applications/Products

Hydraulic Brake Valve Automobile Wheels

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Brake master Cylinder

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Commercial features

Door Pillars for Audi

Control arms for Steering Fiat Engine bracket Semi-solid Metal processing by Dr. Muhammad Kamran April 30, 2009

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Future Developments
Process development

Mechanism of formation of non-dendritic

structure Alloy development Simulation studies of process Viable process for steel and Cast Iron

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Thank You for Your Patience

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