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Rapid Slurry Forming (RSF) Technology :: Total Materia Article
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Rapid Slurry Forming (RSF) Technology
Rapid slurry formation (RSF) is a novel semi-solid metal forming technique which allows complex geometries to be formed in a single operation.
Advantages of RSF include a much reduced suspension preparation time and cost and most importantly te ability to achieve a globular structure and high fluidity of suspension at te same time.
Rapid slurry formation is a semi-solid metal forming technique, which is based on a so-called solid enthalpy exchange material (EEM). It is a fascinating technology offering te opportunity to manufacture net-shaped metal components of complex geometry in a single forming operation.
Te RSF process differs from other rheocasting processes because heat extraction and temperature control are not necessary. Te RSF process is based on enthalpy exchange of two alloys where one alloy is te low superheat melt (high enthalpy).
Te other one acts as te cold solid stirring material (low enthalpy) and is also known as enthalpy exchange material (EEM). During te process te EEM is submerged into te melt while stirring action is applied. Heat is absorbed from te melt during stirring operation, and te two alloys with different enthalpies will form a new alloy system with a new enthalpy level.
RSF technology is able to extract a very large amount of heat through enthalpy exchange of similar material in a very short time. This also improves te castability of te alloy significantly. Te reason being that through RSF technology, te morphology of te primary phase changes from coarse dendrites to near globular, which eliminates te feeding problem during solidification that is associated with conventional casting method.
Te advantage of te method is that te relatively low solid phase fraction (20-30%) provides for achieving a globular structure with simultaneous retaining te high fluidity of suspension, and te preparation of te suspension is much shorter and cheaper than for other methods.
Figure 1: Schematic diagram of heat exchange during slurry formation in RSF process
Figure 2(a) exhibits te typical as-cast structure of A 357 alloy where highly dendritic a-Al phase is present. Whereas Fig. 2(b-f) show semi-solid structures of A357 alloy at different rpm. One can see change in dendritic morphology of a-Al in semi-solid structure. This improves te castability of te alloy significantly. Te reason being that through RSF technology, te morphology of te primary phase changes from coarse dendrites to near globular, which eliminates te feeding problem during solidification that is associated with conventional casting method.
Figure 2: Optical Microstructures of A357 alloy at different rotation speed: (a) 0 rpm, (b) 450 rpm, (c) 800 rpm, (d) 1200 rpm, (e) 1400 rpm and (f) 1800 rpm
1. L.Ratke, A.Sharma, D.Kohli: Effect of process parameters on properties of Al-Si alloys cast by Rapid Slurry Formation (RSF) technique, IOP Conf. Series: Materials Science and Engineering 27 (2011) 012068 doi:10.1088/1757-899X/27/1/012068;
2. A.Sharma: Synthesis of semi solid slurry and effect of inoculants on microstructure of A356 alloy cast by rapid slurry forming (rSF) process, La Metallurgia Italiana - n. 4/2013, p.53-58;
3. Z.Konopka, M.Lagiewka, M.Nadolski, A.Zyska: Theoretical analysis of te AlSi10Mg alloy suspension manufacturing by te RSF process, Archives of Metallurgy and Materials, Vol.55, Issue 3, 2010, p.869-873;
4. L.Ratke, A.Sharma, D.Kohli: Te RSF Technology for Semi-Solid Casting Processes, Technical Paper, Indian Foundry Journal, Vol.57, No10. October 2011, p.33-36
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