Semisolid Processes

Govender, Gonasagren; Möller, Heinrich; Damm, Oliver

doi:10.1016/b978-0-08-096532-1.00516-1

Cited by 4 publications

(4 citation statements)

References 51 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…High-pressure die casting (HPDC) is a common process for casting nonferrous metals. It is particularly suited for the high-volume production of complex near-net shapes [1,2]. The majority of casting alloys are based on the secondary alloys Al-9Si and Al-12Si [3].…”

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Investigations into Heat Transfer Using a Jet Cooler in High-Pressure Die Casting

Bohacek,

Mraz,

Krutis

et al. 2023

JMMP

View full text Add to dashboard Cite

During high-pressure die casting, a significant amount of heat is dissipated via the liquid-cooled channels in the die. The jet cooler, also known as the die insert or bubbler, is one of the most commonly used cooling methods. Nowadays, foundries casting engineered products rely on numerical simulations using commercial software to determine cooling efficiency, which requires precise input data. However, the literature lacks sufficient investigations to describe the spatial distribution of the heat transfer coefficient in the jet cooler. In this study, we propose a solver using the open-source CFD package OpenFOAM and free library for nonlinear optimization NLopt for the inverse heat conduction problem that returns the desired distribution of the heat transfer coefficient. The experimental temperature measurements using multiple thermocouples are considered the input data. The robustness, efficiency, and accuracy of the model are rigorously tested and confirmed. Additionally, temperature measurements of the real jet cooler are presented.

show abstract

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Investigations into Heat Transfer Using a Jet Cooler in High-Pressure Die Casting

Bohacek,

Mraz,

Krutis

et al. 2023

JMMP

View full text Add to dashboard Cite

show abstract

“…Even if the technology was developed in the 70's [1], the first commercial application was presented only at the end of 90's by UBE at the GIFA International Foundry Trade Fair. [2]. Like Thixocasting, it creates a globular microstructure, contrary to the dendritic structure seen in other foundry processes -with all its obvious advantages [3,4].…”

Section: Introductionmentioning

confidence: 99%

Producing Structural High Integrity Castings with Minimum Carbon Footprint with the Comptech-Rheocasting Process

Hartlieb,

Tawil,

Bergeron

et al. 2023

SSP

View full text Add to dashboard Cite

Structural high vacuum die casting has been growing significantly over the past decades. It is typically done with special (primary type) alloys, special melt treatment practices, high vacuum, a carefully engineered die casting process applying many best practices in our industry. Structural die castings are growing in size and complexity and die casting machines are getting bigger and bigger - and those castings are becoming a significant challenge with current technologies. It was now found that Rheocasting - a process of preparing a semi-solid slurry (with 30-45% solid fraction) that is injected slower and in a laminar way into the cavity, can take structural die casting to completely new heights, enable the casting of parts that would otherwise be impossible to cast and at the same time reduce or eliminate some of the current problems of structural die casting. With Rheocasting, lower purity (secondary) aluminum alloys can be used and excellent properties can be achieved as cast and heat treated (T5, T6/7). Rheocasting has had a breakthrough in the telecom and other industries, but it has now been optimized to become an essential tool in the toolbox of making structural castings. This paper shows the developments that lead to the successful series production of a large (about 4’ long) hinge pillar for an Electric Vehicle (EV). It explains the challenges and how they were overcome, and some of the possibilities of the process regarding alloys, heat treatments and achievable properties. It also shows how Rheocasting can help die casters produce more complex (thin and thick walled) and very large castings with the highest integrity. It can replace structural low-pressure permanent mold (LPPM) castings and reduce wall thickness, improve tolerances and make them more economical. Rheocasting can enable die casters to enter this new market of structural castings including Gigacastings, produce parts previously thought impossible to cast (and on much smaller machines than thought), and expand the growing structural die casting market even faster and further.

show abstract

“…Rheocasting, as one branch of semi-solid casting beside thixocasting, was introduced early in this this century as a cost efficient casting process [4]. Several different rheocasting processes were developed at universities around the world but just a few of them reached industrial maturity [5]. One of them being the so called Rapid-S Process developed and patented by company Rheometal [6].…”

Section: Introductionmentioning

confidence: 99%

Manufacturing and Fatigue Verification of Two Different Components Made by Semi-Solid Processing of Aluminium TX630 Alloy

Blad

Johannesson

Nordberg³

et al. 2016

SSP

View full text Add to dashboard Cite

Although rheocasting is widely used for the production of thin-walled components, thick-walled rheocast components are not yet common. In this paper, thick-walled semi-solid cast components were manufactured using serial production equipment. The aim of the investigation was to replace components made of spheroidal graphite cast iron (SGI) and conventionally cast aluminium in order to lower the weight of the truck, and still fulfill the high demands set on serial production. The rheocasting process used was a modified Rapid-S process coupled with a TX630 aluminium alloy and T5 or T7 heat treatment. Two different serial production rheocast components were fatigue tested by means of constant amplitude rig testing in order to define Wöhler curves. Moreover, multi-axial shake testing with signals recorded from proving ground was carried out. Fracture surfaces as well as metallographic samples were investigated.

show abstract

Semisolid Processes

Cited by 4 publications

References 51 publications

Experimental and Numerical Investigations into Heat Transfer Using a Jet Cooler in High-Pressure Die Casting

Experimental and Numerical Investigations into Heat Transfer Using a Jet Cooler in High-Pressure Die Casting

Producing Structural High Integrity Castings with Minimum Carbon Footprint with the Comptech-Rheocasting Process

Manufacturing and Fatigue Verification of Two Different Components Made by Semi-Solid Processing of Aluminium TX630 Alloy

Contact Info

Product

Resources

About