semi solid metal forming
TRANSCRIPT
Pierre Rossouw
02 December 2010
Semi-Solid Metal Forming
© CSIR 2010 www.csir.co.za
© CSIR 2010 www.csir.co.za
• Background
- Organogram of MSM
- Research Focus (ACT)
• SSM Forming
- Background
- CSIR’S Approach
- Current Research
• Casting Alloys
• Wrought Alloys
• Product Development
- Future
Outline
BackgroundMMP Organogram
Powder Metallurgy Technologies
Dr Hilda Chikwanda
Advanced Casting Technologies
Dr Sagren Govender
Engineering Design & AnalysisVacant
Metals & Metals ProcessesDr Willie du Preez
CA AssistanceChristelle Stearn
Mary MojalefaRebecca Myelase(contr)
Quality FacilitationChristelle Stearn
Jeff BensonDr Chris Machio
Dr Lethu ChikoshaMaje Phasha
Sylvester BolokangTafadzwa Mushove
Given LesejaneLerato Raganya (intern)
Pierre RossouwHein MöllerUlyate Curle
Kalenda MutomboSigqibo Camagu
Nonjabuliso MazibukoPeter Malesa
Sam PapoDr Lillian Ivanchev(IC)
William Tefu (contr)
Gary CorderleyLesley Harris
Markus CoetzerFilipe Pereira Danie Wilkins
Martin WilliamsMarius Grobler
David Ntuli (contr)
Primary Processes
Dawie van Vuuren
Ronel LaageShaan OosthuizenGhislain TshilomboEugene Swanepoel
Jaco SwanepoelDewald Terblanche
Danie Snyman
Pro
ject
Man
agem
ent
Nee
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abst
, Dun
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MMP LaboratoryMechanical Testing, Metallurgical & High Temperature Materials Testing
Visiting Researchers
Chris McDulingErich GüldenpfennigSuzan Nchabeleng (100%)
Danie Snyman (20%)Dr Wim Richter (20%)
CSIR-CermalabBruce Berger (Ops. Man.)
CSIR-CermalabBruce Berger (Ops. Man.)
Levy Chauke
© CSIR 2010 www.csir.co.za
© CSIR 2010 www.csir.co.za
Advanced Casting
HPDC•New tool materials•Improving net yield•Foundry practice for Al•Development of a VIVC HPDC Machine•Squeeze casting•Near Net shape forming of AlMMCs
SSM•SSM processing of aluminium alloys•Heat treatment of SSM castings•Development of the CSIR-RCS•Near Net shape forming of AlMMCs
Investment Casting
•Titanium(90%)•Counter gravity casting of Aluminium Magnesium alloys(5%)•Near net shape forming of AlMMCs(5%)
Funded by CSIR Parliamentary Grant and LMDN
Funded by DST
Funded by LMDN
Funded by CSIR Parliamentary Grant
BackgroundOverview of Casting Research
1. THIXOFORMING
2. RHEOCASTING
Semi-Solid Metal Forming Background
© CSIR 2010 www.csir.co.za
• High wall thicknesses and different wall thicknesses can be designed
• Low gas porosity due to laminar filling and good airing
• Low solidification porosity due to a high solid fraction proportion (fsolid ~50%)
• Production of thin walled components
• Allows for the casting of wide range of alloys inclusive of highstrength wrought alloys.
• Joining by LASER, MIG or WIG welding possible
• Heat treatment from T0 - T7 possible
• Near netshape or netshape parts production
• Improved tool life
Semi-Solid Metal Forming Background - Potential Benefits
© CSIR 2010 www.csir.co.za
Liquidus temperature
Solidus temperature
LIQUID
SEMI-SOLID
SOLID
•CASTING
•HOT FORMING
•SEMI-SOLID METALCASTING/FORMING
Known since 3000 BC
Known since 3500 BC
Ambient temperature
•COLD FORMINGKnown since 4000 BC
Known since 1973 AD
THIXO RHEO
Globular structureformation
Semi-Solid Metal Forming Background – Thixo VS Rheocasting
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SSM FEEDSTOCK
SSM FORMING PROCESS
Semi-Solid Metal FormingBackground- Thixoforming
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Disadvantages
• High cost of feedstock material compared to normal foundry alloys
• In order to meet production rates multiple induction heating stations are required which requires high capital expenditure
• The scrap produced cannot be recycled on site and is also devalued significantly
• The feedstock is supplied in specific lengths, which means there would be additional scrap created by off cuts.
• During reheating oxidation of the billet surface occurs therefore dies have to be designed to remove oxides during the forming process.
• During reheating there are liquid metal losses from the billet prior to casting.
Semi-Solid Metal FormingBackground- Thixoforming
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High Pressure Die Casting
Liquid Metal Semi-solid metal with round grain structure
Cool Transfer
Semi-Solid Metal FormingBackground- Rheocasting
© CSIR 2010 www.csir.co.za
Advantages Disadvantages Cost of material same as standard casting alloys
Semi-solid state achieved direct from liquid.
Oxidation reduced – reduced oxide entrapment.
Reduced loss of metal during reheating.
SSM scrap can be recycled in house.
Hydrogen Absorption
Process consistency
Semi-Solid Metal FormingBackground- Rheocasting
© CSIR 2010 www.csir.co.za
© CSIR 2010 www.csir.co.za
• 2000 – 2002 Rheo-casting process Developed and patented
• 2003 – 2005 Development of industrial prototype –CSIR funded
• 2006 – 2010 - Development of the CSIR-RCS - SSM forming of Al alloys- Heat treatment - Development of component for SSM forming- Established Research Infrastructure- Commercialisation of CSIR-RCS
Semi-Solid Metal FormingBackground- SSM Forming Research in SA
SSM Research at the CSIRGoal
© CSIR 2010 www.csir.co.za
To provide the total SSM product solution to the prospective client
• Process Development•RCS•HPDC
•Material•Alloy•Heat treatment•Material property
•Product•Customer specification•Product design•Die design•Product qualification•Lifeing
© CSIR 2010 www.csir.co.za
SSM Research at the CSIRApproach
Overview of SSM research• Development of the CSIR-RCS for
commercialisation• SSM processing of cast and wrought
aluminium alloys• Heat treatment• Corrosion• Mechanical properties• Product development
© CSIR 2010 www.csir.co.za
SSM Research at the CSIRResearch Areas
© CSIR 2010 www.csir.co.za
SSM Research at the CSIRInfrastructure
130 Ton Shot Controlled HPDC Machine
CSIR – RCS Lab Prototype
© CSIR 2010 www.csir.co.za
SSM Research at the CSIRInfrastructure
© CSIR 2010 www.csir.co.za
Dosing Furnace
630 Ton LK shot control die casting machine
Industrial scale prototype of CSIR SSM billet machine
SSM Research at the CSIRInfrastructure
© CSIR 2010 www.csir.co.za
Other Cast Wrought MMC
Pure Al A356 2024 SiCp/Al
Al-12Si F357 6082
A206 6004
A201 6005
7075
7150
7278
SSM Research at the CSIRAlloys Processed
SSM Processing of Casting
Alloys
© CSIR 2010 www.csir.co.za
© CSIR 2010 www.csir.co.za
A356, F; Etched F357; F; Etched
A356, T6; Etched
SSM Research at the CSIRMicrostructure of SSM formed A356 & F357
F357, T6; Etched
© CSIR 2010 www.csir.co.za
Alloy YS /MPa UTS /MPa Elongation /%
A201-T6(Low Mn)
297 407 13.4
A356-T6(0.35% Mg)
261 317 6.7
F357-T6(0.62% Mg)
312 355 6.0
Note: The properties presented are very dependent on composition and heat treatment process applied.
SSM Research at the CSIRTensile properties obtained for Casting Alloys
© CSIR 2010 www.csir.co.za
SSM Research at the CSIRInfluence of Mg on Tensile properties of A356/F357 Alloys
© CSIR 2010 www.csir.co.za
30
40
50
60
70
80
90
100
110
120
130
0 1 10 100
t at 180oC (h)
VH
N
6082: 0NA6082: 120NA6004: 0NA6004: 120NAA356: 0NAA356: 120NA
SSM Research at the CSIRHeat Treatment of Cast and Wrought Alloys
© CSIR 2010 www.csir.co.za
SSM Processing of Wrought
Alloys
© CSIR 2010 www.csir.co.za
7075 with no TiB2; F; Etched 7075 with medium TiB2; F; Etched
7075 with high TiB2; F; Etched
SSM Research at the CSIRMicrostructure of SSM formed GR 7075
© CSIR 2010 www.csir.co.za
no TiB2; T6; Etched
SSM Research at the CSIRMicrostructure of SSM formed GR 7075
7075 with medium TiB2; T6; Etched
7075 with high TiB2; T6; Etched
© CSIR 2010 www.csir.co.za
• Tensile test results; T6
Alloy YS /MPa UTS /MPa Elongation /%
no TiB2 467 513 3.2
medium TiB2 458 516 4.5
high TiB2 453 516 5.3
Minimumspecification 455 531 7.0
SSM Research at the CSIRTensile properties obtained for GR 7075
© CSIR 2010 www.csir.co.za
• Tensile results relative to minimum specification; T6
Alloy YS /% UTS /% Elongation /%
no TiB2 103 97 46
medium TiB2 101 97 64
high TiB2 100 97 76
SSM Research at the CSIRTensile properties obtained for GR 7075
© CSIR 2010 www.csir.co.za
• Microstructure: 2024
F T6(Etched)
SSM Research at the CSIRMicrostructure of SSM Processed Wrought Alloys
© CSIR 2010 www.csir.co.za
• Microstructure: 6082
F T6(Etched)
SSM Research at the CSIRMicrostructure of SSM Processed Wrought Alloys
© CSIR 2009 www.csir.co.za
• Microstructure: 7075
F T6(Etched)
SSM Research at the CSIRMicrostructure of SSM Processed Wrought Alloys
© CSIR 2010 www.csir.co.za
Alloy YS /MPa UTS /MPa Elongation /%
2024-T6 351 385 5.1
Spec. min. 345 427 5.0
6082-T6 341 365 3.6
Spec. min. 260 310 10.0
7075-T6 467 513 3.2
Spec. min. 455 531 7.0
SSM Research at the CSIRTensile properties obtained for Wrought Alloys
© CSIR 2010 www.csir.co.za
Tensile results relative to minimum specification
Alloy YS /% UTS /% Elongation /%
2024-T6 102 90 102
6082-T6 131 118 36
7075-T6 103 97 46
SSM Research at the CSIRTensile properties obtained for Wrought Alloys
© CSIR 2010 www.csir.co.za
© CSIR 2010 www.csir.co.za
SSM HPDC High Purity Aluminium
SSM Research at the CSIRMicrostructure of SSM Processed High Purity Al
© CSIR 2010 www.csir.co.za
Conventional Eutectic (No SSM Processing)
Eutectic Rheo-processed and HPDC
SSM Research at the CSIRMicrostructure of SSM Processed Al-Si Eutectic Alloy
© CSIR 2010 www.csir.co.za
• SSM Castings - Produced using the Industrial Scale HPDC Cell
• CSIR-RCS• Dosing Furnace• LK 630 ton shot controlled HPDC machine
- Alloy - A356
• Main Objective:- Demonstrate process consistency
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SSM Research at the CSIRSSM HPDC of a Brake Calliper
SSM Research at the CSIRSSM HPDC of a Brake Calliper
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Surface Liquid Segregation
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SSM Research at the CSIRSSM HPDC of a Brake Calliper
© CSIR 2009 www.csir.co.za
SSM Research at the CSIRSSM HPDC of a Brake Calliper
50
70
90
110
130
150
0 2 4 6 8 10 12 14 16 18 20
Depth (mm)
VH
NFT4 (540-1)T4 (540-6)T5 (180-4)T5 (170-6)T6(540-1,20NA,180-4)T6(540-6,20NA,170-6)
Hardness profiles through a cross section of SSM-HPDC brake calipers
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Original componentComponent redesigned for SSM forming
SSM Research at the CSIRProduct Development Case Study – Engine Mounting Bracket
© CSIR 2010 www.csir.co.za
© CSIR 2010 www.csir.co.za
X-ray Analysis of a Casting
SSM Research at the CSIRProduct Development Case Study – Engine Mounting Bracket
© CSIR 2010 www.csir.co.za
Mechanical Properties
Summary of Mechanical Properties from Selected Castings
Condition HB YS, MPa
UTS, MPa
A, %
F 71.2 104.3 180.0 5.2 T4 84.0 144.3 255.4 13.3 T6 109.7 255.5 315.2 5.38 T5 91.6 194.0 262.3 4.7
Minimum requirements
85 167 275 1.5
Tensile samples were machined from this section
SSM Research at the CSIRProduct Development Case Study – Engine Mounting Bracket
• Partner interest after initial discussions:- Component is identified- Al-alloy of wrought composition- Must meet minimum requirements of the customer
- Mechanical properties- Cost
- Partner to specify other applicable material properties
• Intent:- Willing to apply CSIR-RCS technology if successful - Create manufacturing facility with jobs in South Africa
(Localisation)
SSM Research at the CSIRProduct Development – New Opportunities
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CSIR-RCS: Large scale (2)
Preliminary Work
• Component: Engine mounting bracket- Commercial 7075 (~ 150 kg furnace); A356- Rheo-processing parameters (pouring & SSM temp.)- HPDC shot parameters (velocity profile & intensification)� X-ray evaluation (defects)� Heat treatments (apply knowl. from plates)� Mechanical properties (compare with knowl. from plates)
• Aim:Preparation of niche component production
SSM Research at the CSIRProduct Development – New Opportunities
© CSIR 2010 www.csir.co.za
© CSIR 2010 www.csir.co.za
• Product development for client• SSM forming of high strength wrought alloys• Optimisation of heat treatments• Alloy development• Develop data base of mechanical properties
- Tensile- Fatigue- Fracture
• Evaluation surface properties- Corrosion- Coatings
© CSIR 2010 www.csir.co.za
SSM Research at the CSIRFuture Work
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