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Semi-Solid Metal (SSM) Processing - A New Approach To Metal Casting
Semi-Solid Metal (SSM) Processing - A New Approach To Metal Casting
By
Property exploited is
Rheology
Steady state rheology (Rheology)
Transient state rheology (Pseudoplasticity)
Time dependent rheology (Thixotropy)
dendritic arms
Bending and shearing of
secondary arms
Fragments of primary dendrites
grow into globular grains under
forced convection
April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 3
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 liquid-
solid interface energy
Characteristics of Slurry
Sheared semi-solid slurry
shows apparent viscosity
similar to machine oil
April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran Composition, Time 5
Alloy Characteristics
Solidification range
Low melting point
phase/eutectic phase
Temperature Sensitivity of solid
fraction
Fraction Solid
Castability
Potential for aging etc.
Processing Range
Temperature
solid range
Compocasting
Shearing a miscible or immiscible mixture of
Grain refinement
Spray forming and sintering
Ultrasonic vibrations etc.
Mechanical Stirring
Megnatohydrodynamic (MHD) Stirring
Stress Induced and melt Activated (SIMA)
Process
Spray Forming
Liquidus Casting
Ultrasonic treatment
Grain refienment etc.
April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 10
Semi-solid Metal Processing
Techniques
Mechanical Stirring
Developed at MIT
while controlled
cooling in the semi-
solid range using
auger, impeller or
paddle
Batch type or
continuous process
For Rheocasting and
Thixocasting
Grain Refinement
Promote heterogeneous nucleation
Mechanical stirring
MHD Stirring
New Rheocasting (NRC)
suitable feedstock
Mechanical stirring
MHD stirring
SIMA process
Spray forming
Thixocasting
Thixoforging
Controlled atmosphere
Twin Screw
Rheomoulding
(TSRM) process is an
upgradation
April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 19
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
Automobile Wheels
Control
April 30, 2009arms for Steering FiatKamran
Semi-solid Metal processing by Dr. Muhammad Engine bracket 24
Future Developments
Process development
Mechanism of formation of non-dendritic
structure
Alloy development
Simulation studies of process
Viable process for steel and Cast Iron