Semi-solid Metal (SSM) Processing

– A New Approach to Metal

Casting

By

Dr. Muhammad Kamran

Introduction
 Discovered at MIT
 in 1971
 During study of hot tearing of steel during
solidification
 Modeled by Sn-15Pb alloy using Coeutte
Rheometer

 Semi-solid Metal Processing

 Non-dendritic structure
 Solid-liquid region
 Suitable fraction solid

 Property exploited is
 Rheology
 Steady state rheology (Rheology)
 Transient state rheology (Pseudoplasticity)
 Time dependent rheology (Thixotropy)

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 2

Evolution to Non-dendritic
Microstructure
 Under Forced Convection
 Fragmentation of primary
dendrites by
 Root melting of secondary

dendritic arms
 Bending and shearing of

secondary denritic arms

 Bending and root melting 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

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 4

Introduction

 Characteristics of Slurry
Sheared semi-solid slurry
shows apparent viscosity
similar to machine oil

 SSM Processing exploits Conventional

solidification
T
Solidification mechanism Semi-solid Processing

in the solid-liquid range Liquid

+ Liquid
Solid
i.e. nucleation and growth
mechanisms Solid

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

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 6

Introduction

 Classification suggested by Flemings et.Al.

 Rheocasting
 Shearing the liquid while cooling from liquid to liquid –

solid range and casting a net-shape product

 Thixocasting
 Shearing a partially melted suitable precursor in semi-

solid range
 Compocasting
 Shearing a miscible or immiscible mixture of

composite in the solid-liquid range

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 7

Evolution to Non-dendritic
Microstructure
 Other Mechanisms

 Grain refinement
 Spray forming and sintering
 Ultrasonic vibrations etc.

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 8

Processing Techniques
 Techniques for feed stock
 Techniques for Finished Product

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 9

Semi-solid Metal Processing Techniques

 Techniques for non-dendritic Feedstock

 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

 Stirring of liquid alloy

while controlled
cooling in the semi-
solid range using
auger, impeller or
paddle
 Batch type or

continuous process
 For Rheocasting and

Thixocasting

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 11

Semi-solid Metal Processing
Techniques
 Magnetohydrodynamic (MHD) Stirring

 Patented by Alumax Inc.

 Vigorous stirring by rotating magnetic field within the
mould
 Normally for producing feedstock for thixocasting
 Disintegrated fine dendrites which convert to globular
grains on partial melting
 Most widely used process

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 12

Semi-solid Metal Processing
Techniques
 Stress Induced and Melt Activated (SIMA) Process
 Severe deformation of precursor results in residual
stresses
 On heating recrystallisation occurs

 On partial melting low melting point phase becomes

liquid
 High residual stress favours wetting of grain
boundaries
 Higher curvature and liquid-solid interface energy
favours globular grain morphology

 Longer holding time favours coarsening and

agglomeration which deteriorate semi-
solidprocessability
April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 13
Semi-solid Metal Processing
Techniques
 Liquidus Casting
 Pouring of melt at near-liqudus temperature

 Higher rate of Nucleation favouring fine grain size

 On partial melting fine grains transform to globular

grains

 Grain Refinement
 Promote heterogeneous nucleation

 Finer grain size

 Grains transform to globular on partial melting

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 14

Semi-solid Metal Processing
Techniques
 Techniques for Net-shape Product
 Rheocasting
 Thixoforming
 Thixomoulding
 Rheomoulding etc.

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 15

Semi-solid Metal Processing
Techniques
 Rheocasting
 Non-dendritic ally slurry obtained from shearing while
cooling from liquid state

 Mechanical stirring
 MHD Stirring
 New Rheocasting (NRC)

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 16

Semi-solid Metal Processing
Techniques
 Thixocasting
 Partial melting of

suitable feedstock

 Mechanical stirring
 MHD stirring
 SIMA process
 Spray forming

 Thixocasting
 Thixoforging

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 17

Semi-solid Metal Processing
Techniques
 Thixomoulding®
 Simultaneous heating and shearing of solid feedstock

in a chamber by rotating barrel

 Designed for Mg alloy

 Controlled atmosphere

 Similar to injection moulding

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 18

Semi-solid Metal Processing
Techniques
 Rheomoulding
 Vigorous Shearing of
liquid alloy using
screw type drive
while cooling
 Similar to Injection
moulding
 Suitable even for
immiscible alloy
formation and
processing

 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

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 20

Commercial features
 Disadvantages
 Relatively higher feedstock material cost
 Precise control of operating condition is
required.
 Liquid segregation may occur as a result of
non-uniform heating

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 21

Commercial features
 Potential Applications
 Replacement of permanent mould parts to eliminate
machining and finishing
 Pressure tight parts such as master brake cylinders,
fuel rails, air conditioner compressor housing etc.
 High strength parts such as engine mounts, tie rods
etc.
 Wear resistant parts made from hypereutectic alloys
such as compressor piston, brake drums, gear shift
levers etc.
 Forged parts requiring excessive tooling

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 22

Commercial features
 Current Applications/Products

Hydraulic Brake Valve

Automobile Wheels

Brake master Cylinder

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 23
 Commercial features

Door Pillars for Audi

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

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 25

 Thank You for Your Patience

April 30, 2009 Semi-solid Metal processing by Dr. Muhammad Kamran 26