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Semi-Solid Processing (SSP) of Alloys: Part Two :: Total Materia Article
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Semi-Solid Processing (SSP) of Alloys: Part Two
Since its commercial launch in te 1980’s semi-solid processing (SSP) has offered possibilities to manufacture components from alloys which otherwise would have been impossible to achieve, in particular within te automotive and aerospace industries.
Thixocasting and rheocasting are two main routes following te SSP process and although both are confined to specific casting niches, both can produce excellent quality product with much improved mechanical properties when compared to traditional processing methods.
Semi-solid processing (SSP) of alloys has been used commercially since te early eighties for te manufacture of components in te automobile and aerospace industries. Te thrust of te early development has been in aluminum and copper alloys. Te nature of te process makes it an ideal candidate for te manufacture of components in alloys which are either difficult or virtually impossible to forge by conventional means. Alloys such as tool steels, stellites and superalloys, offer te possibility of a lucrative niche for commercial exploitation.
Te key difference of te semi-solid process is te reduced temperature when compared to te casting of superheated melts. Te generally accepted advantages of hardware performance and energy economy, achieved due to reduced operating temperatures, are universally positive for all alloys and include te following: lower energy consumption, no handling of liquid metal, longer die life, better yield from te raw material due to lower oxidation and evaporation, and fewer other losses related to melt overheating.
While these benefits are related to hardware performance, te reduced processing temperature also replaces a molten alloy with a semi-solid slurry. Then, further reduction in temperature below te liquidus changes te solid/liquid ratio and slurry properties which in turn affect te final product, not only in terms of its internal integrity, but also its microstructure.
It should be noted that semi-solid processing bases were established by studying low melting point alloys such as aluminum and magnesium alloys which are now commercialized. So far, te SSP technology has not been applied on an industrial scale for high melting point alloys such as steels, but over time there have been several key researches on several steel grades that are more likely to be processed by this new technology.
Te two major routes that are used to form semi-solid metal are thixocasting and rheocasting. In thixocasting, grain–refined billets are reheated to te semi-solid range and formed into near-net-shape parts. Thixocasting can yield high-quality parts with high mechanical properties. In contrast, rheocasting involves preparing semi-solid metal from te melt using a specific technique. High feedstock material cost and high capital investment of thixocasting make it desirable only in niche applications.
Figure 1 shows a common SMM process routes.
Semisolid metal processing (SSM) or thixoforming is a new technology that offers several advantages over liquid processing and solid processing. This process utilizes semisolid behavior as well as reduces macrosegregation, porosity, and forming forces during te shaping process. A lot of research work has been carried out by various researchers in order to exploit te potential of this process to produce different products especially for te automotive industry.
In te paper of Salleh M.S. et al. te rheological behavior of aluminum alloys in semisolid slurries, thixoformability of modified aluminum alloys, te effect of feedstock production method on mechanical properties, and te importance of developing low-cost raw materials for semisolid processing are summarized.
Figure 1: SMM process routes
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Semi-Solid Processing (SSP) of Alloys: Part One
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