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Die design method for thin plates by indirect rheo-casting process and
effect of die cavity friction and punch speed on microstructures and
mechanical properties
Chul Kyu Jin a , Chang Hyun Jang a , Chung Gil Kang b,
a
Precision Manufacturing System Division, Graduate School, Pusan National University, San 30 Chang Jun-dong, Geum Jung-Gu,
Busan 609-735, South Korea
b
Engineering Research Center for Net Shape and Die Manufacturing, School of Mechanical Engineering, Pusan National University, San 30 Chang Jun-dong,
Geum Jung-Gu, Busan 609-735, South Korea
a r t i c l e
i n f o
Article history:
Received 12 November 2014
Received in revised form 28 April 2015
Accepted 1 May 2015
Available online 12 May 2015
Keywords:
Semi-solid slurry
Indirect rheo-casting
Electromagnetic stirring
Thin plate
Filling simulation
A356 alloy
a b s t r a c t
Thin plates with a thickness of 1.2 mm are fabricated from semi-solid A356 alloy through an indirect
rheo-casting process both with and without an electromagnetic stirrer (EMS). The thin die cavity for
forming is designed with the uid analysis software MAGMA. A semi-solid slurry with a solid fraction of
40% is prepared and then injected into the die of a 200 t hydraulic press. Forming tests are performed on
the thin plates at two punch speeds (30 and 300 mm/s) and two cavity friction conditions (mf = 0.4 and
mf = 0.9). The formability, mechanical properties, and microstructure are then evaluated. The semi-solid
slurry obtained with an EMS contains ne and globular solid particles; the semi-solid slurry produced
without an EMS reveals rosette particles and coarser globular solid particles. At high friction (mf = 0.9),
the cavity is mainly lled with the liquid phase. At a higher punch rate, the thin plates show better
formability and a microstructure with ne and even solid particles. The tensile strength and elongation
of the thin plate formed with a punch speed of 300 mm/s in the cavity with graphite lubrication (mf = 0.9)
are 216 MPa and 10%, respectively. These values are 57 MPa and 5.5% higher, respectively, than those of
the thin plate formed at a punch speed of 30 mm/s.
2015 Elsevier B.V. All rights reserved.
1. Introduction
The die casting process for aluminium involves the high-speed
injection of molten metal, which leads to internal defects because
of remaining gas or air in the molten metal, which in turn deteriorates the mechanical properties. Niu et al. (2000) found that the
volume of gas porosity and the pore sizes in the castings are significantly reduced through the use of a vacuum during die casting.
This markedly improves the density and mechanical properties,
particularly the tensile strength and ductility. The forging process has limited formability of near-net shapes and reduces the
after-treatment productivity and die life, which makes eco-friendly
production impossible. Squeeze casting is a metal forming process
where molten metal is solidied under a relatively high pressure to
reduce gas or shrinkage porosity. However, this process produces
a rosette and dendrite structure (Yue and Chadwick, 1996) and has
Corresponding author. Tel.: +82 51 510 1455; fax: +82 51 518 1456.
E-mail address: cgkang@pusan.ac.kr (C.G. Kang).
http://dx.doi.org/10.1016/j.jmatprotec.2015.05.002
0924-0136/ 2015 Elsevier B.V. All rights reserved.
C.K. Jin et al. / Journal of Materials Processing Technology 224 (2015) 156168
rheo-moulding process, and Fan et al. (2005) presented a rheodiecasting (RDC) process which directly uses liquid Al alloys.
Their results indicated that the RDC samples had close to zero
porosity and a ne and uniform microstructure throughout the
entire sample under the as-cast condition. Atkinson (2005) summarised routes to spheroidal microstructures, types of semi-solid
processing, the advantages and disadvantages of these routes, the
background rheology, mathematical theories of thixotropy, the
transient behaviour of semi-solid alloy slurries, and computational
modelling.
The one major drawback of rheo-forming or thixoforming for
processing semi-solid metals is controlling the liquid or solid segregation (i.e., separation of the solid and liquid phases or uneven
distribution of the solid phase). When a semi-solid slurry lls the
die, the material comes in contact with the cavitys wall. This
causes uneven ows leading to segregation of the solid phase
(primary -Al particles) from the liquid phase. Chen and Tsao
(1997) proposed semi-solid deformation mechanisms and predicted the segregation phenomenon based on deformation of a
phenomenological model. Kang et al. (2007) investigated the effect
of changing the injection velocity on the globular microstructure
and mechanical properties of a product from semi-solid die casting. They found that the difference in the solid fraction between
samples with and without liquid segregation was approximately
1520%. For thin plates, segregation of the solid and liquid phases
can be more severe, which makes their mechanical properties
uneven at different locations. Because of the problems associated
with segregation and the low initial forming temperatures for
semi-solid metal processing, no research has been carried out so
far on the fabrication of thin plates with the rheo-forming process.
In this study, an indirect rheo-casting process was applied to
compensate for the disadvantages of indirect squeeze casting and
produce aluminium thin plates for electric and automobile parts
and fuel cell bipolar plates. The indirect rheo-casting process for
thin plates involves a low pouring temperature in a thin die cavity. This makes it highly likely that the material will fail to ll the
cavity entirely and solidify starting from the centre, which will
result in incomplete forming. Therefore, the aim of this study was
to nd ways to design a die for indirect rheo-casting which are
appropriate for the thin plates shape. A gate shape and overow
adequate for rheological behaviour were designed with the software MAGMA to allow the semi-solid slurry to ll the cavity. The
A356 alloy with a wide solid-liquid coexistent region was used as
the semi-solid slurry. A semi-solid slurry with ne and globular
solid particles was fabricated through the use of an electromagnetic stirrer (EMS) to control the grain size of the A356 alloy.
The semi-solid slurry was injected into a die installed in a 200t hydraulic press to form a thin plate. Experiments for forming
thin plates were performed at two punch speeds and two cavity
friction conditions, and the effect of the punch speed and friction on the formability, microstructure, and mechanical properties
was analysed. The microstructure and mechanical properties of
the formed thin plate samples were measured at different locations.
2. Experimental procedure
formula called a power law is used (Kim and Kang, 2000; Atkinson,
2005):
= k n1
(1)
where is the shear stress, is the shear rate, k is the power law factor, and n is the power law index. When n = 1, the material becomes
a Newtonian uid whose viscosity is the same as k. Kim and Kang
(2000) set n = 1 for the Newtonian uid model. For the Ostwaldde
Waele uid model, which is for the semi-solid state, the experimentally obtained n value was 0.48 to 0.45 (shear rate = 32500 s1 ).
This was applied in MAGMASOFT for comparison of the lling analysis results within the die. Their results demonstrated that the
Ostwaldde Waele uid model is consistent with the experimental results. The viscous behaviour model of MAGMASOFT uses the
Ostwaldde Waele model, which expresses the non-Newtonian
aspect of semi-solid materials through a power law:
n = m n1
(2)
157
Values
Material
Liquidus temperature (TL )
Solidus temperature (TS )
Initial temperature (TM )
430 kJ/kg
Material
Initial temperature (TD )
Material and die
Die and die
A356
617 C
547 C
596 C
SKD 61
300 C
7000 W/m2 K
1000 W/m2 K
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C.K. Jin et al. / Journal of Materials Processing Technology 224 (2015) 156168
Table 2
Chemical composition of A356 alloy (wt%).
Si
Mg
Ti
Fe
Ni
Mn
Zn
Pb
Al
7.08
0.35
0.17
0.08
0.07
0.01
0.01
0.01
Bal.
Fig. 2. Electromagnetic stirrer: (a) real picture and (b) schematic diagram.
vertical to the core. The core for xing the coil position was fabricated by piling up several 0.35 mm thick plates. The core consisted
of 240 unit laminations of SiZn alloy plates, and the coil was wound
around the core. Each phase was placed in a cylindrical direction,
as shown in Fig. 2(b), to let the current move alongside the coil, and
an electromagnetic force was generated in the cylindrical direction to stir the molten metal. The electromagnetic force of the EMS
was measured with a gaussmeter at three positions. Fig. 3 shows
the variations in the magnetic induction density measured at three
positions inside the EMS as a function of the current. The measured
magnetic induction density was proportional to the increase in the
current at each position. At a current of 60 A, the magnetic induction densities at the upper, middle, and lower positions were 640,
680 and 1120 G, respectively. The stirring force induced shear stress
in the molten aluminium, which controlled the growth of dendrite
arms which form during solidication. Thus, it controlled the grain
size of the solid phase and made the grains globular.
Fig. 4 shows the process to make a semi-solid slurry. First, the
cup is inserted into the EMS, and a ladle is used to scoop the molten
metal from the furnace. Then, stirring starts as the electric current
is applied while the molten metal is poured into the EMS cup. (The
molten metal is at a temperature of 680 C in the furnace, 635 C
in the ladle, and 620 C in the cup.) Stirring is performed until the
temperature of the molten metal in the cup cools to 596 C, i.e., the
solid fraction (fs) is 40%. It takes about 78 s of stirring to reach this
level. The variables for the stirring experiment were the molten
metal temperature at the start of stirring (TS ), the stirring current
(A), and the stirring time (t). Bae et al. (2007) suggested that ne
and globular solid particles can form when the molten metal temperature at the start of stirring is below 655 C, the stirring current
is 60 A, and the stirring time is 60 s based on an electromagnetic
stirring experiment using A356. Therefore, in the present experiment, the molten metal temperature was 620 C, and the stirring
current was 60 A, as given in Table 3.
Stainless steel 304 was used for the EMS cup. Stainless steel is
nonmagnetic because it is austenitic, so it is not affected by electromagnetic forces. In addition, stainless steel 304 does not deform
even at temperatures over 700 C. Seo et al. (2002) performed a
compression experiment on a semi-solid slurry and examined how
changes in the height and diameter of the billet affect the liquid segregation. They concluded that a larger billet diameter makes it less
likely for pores and liquid segregation to occur. In addition, a greater
billet length increases the void content gets. Thus, after the amount
of material required for thin plate forming was considered, the EMS
cup was designed to have a similar diameter to the inner diameter
of the die sleeve (60 mm) and a much lower height. Fig. 5(a) and
(b) illustrates the shape dimensions of the EMS cup and actual cup,
C.K. Jin et al. / Journal of Materials Processing Technology 224 (2015) 156168
159
Fig. 4. EMS process for fabricating semi-solid slurry with ne and globular solid particles.
Table 3
Experimental conditions for semi-solid slurry fabrication.
Parameters
Values
Stirring method
Stirring current (A)
Temperature at the start of
stirring (TS )
Temperature at the nish
of stirring (TF )/solid
fraction (fs)
Stirring time (t)
Electromagnetic stirring
60 A
620 C
596 C/40%
60 s
Fig. 6. 200-t hydraulic press with die installed for thin plate fabrication.
Table 4
Experimental conditions for indirect rheo-casting with semi-solid slurry.
Fig. 5. Geometries of stirring cup and slurry: (a) section of cup, (b) photo of cup,
and (c) photo of semi-solid slurry.
Parameters
Value
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Fig. 7. Schematic diagram of indirect rheo-casting process: (a) input semi-solid slurry, (b) forming, and (c) ejecting.
D=
R=
4A
P2
4A
(3)
(4)
Fig. 8. Mould-lling behaviour of semi-solid slurry according to gate shape: (a) straight gate and (b) fan gate.
C.K. Jin et al. / Journal of Materials Processing Technology 224 (2015) 156168
161
Fig. 9. (a) Detail design of fan gate system (unit: mm) and (b) material age.
Fig. 10. Mould-lling behaviour of semi-solid slurry for model with two overows at side: (a) velocity and (b) temperature.
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C.K. Jin et al. / Journal of Materials Processing Technology 224 (2015) 156168
this possibility, the gate was located 4 mm higher than the bottom
part of the biscuit (i.e., around the semi-solid slurry upper part), as
shown in Fig. 9(a). The poor upper part (further solidied) of the
slurry does not ll the cavity and is placed at the area of the semisolid slurry upper part. Fig. 9(b) shows the material age results; the
initial material did not ow into the cavity. The material age refers
to the elapsed time for material inow; a longer time indicates an
earlier material inow.
The fan gate caused the material to ll the entire cavity. The ow
rate at the sides of the cavity increased as well, as shown in Fig. 8(b).
Because the ow at the sides of the cavity reaches the end of the
cavity faster than the ow at the centre of the cavity, the gas or air
in the centre cannot be released through the dies parting line and is
locked inside the cavity instead. The formed sample surface may be
rough at the end of the cavity because of defects such as pores, air
pockets, and ow marks. In addition, an uneven lling speed may
cause the solid and liquid phases to segregate. Therefore, to obtain
a uniform ow rate within the cavity, two overows at the sides
of the cavity were designed. Fig. 10 shows the simulation results
for a model with two overows placed at the sides of the cavity.
As the faster ow on the cavity sides was led to the overows,
the cavity was evenly lled overall. However, when the material
passed through the cavitys centre, the velocity and temperature
dramatically dropped. After the cavity was totally lled, the temperature at the end of the cavity was below 585 C. These may lead
to incomplete lling at the end of the cavity in an actual forming
experiment, which can cause casting defects such as surface cracks
and pores. Because the material portion that solidies at temperatures below 585 C at the end of the cavity can also be removed
with an overow, ve overows were placed at the cavity end, as
Fig. 11. Mould-lling behaviour (temperature) of semi-solid slurry for model with two overows at side and ve overows at end.
Fig. 12. Pressure distribution in cavity for models: (a) two overows at side and ve overows at end, (b) four overows at side and ve overows at end.
C.K. Jin et al. / Journal of Materials Processing Technology 224 (2015) 156168
163
Fig. 13. Indirect rheo-casting die for forming thin plates with semi-solid slurry: (a) photo of real die cavity and (b) die structure.
shown in Fig. 11. The material part that solidied at below 585 C
lled the ve overows at the cavity end, and the temperature in
the cavity was maintained at 590 C.
Fig. 12(a) shows the pressure distribution in the cavity. The
pressure distribution was signicantly uneven. The pressure at the
sides was about atmospheric pressure (1013 mbar). Applied pressure was lost, and some areas were subjected to pressures over
10,000 mbar. The ve overows at the end of cavity were subjected
to atmospheric pressure. The applied pressure was not transferred
Fig. 14. Microstructures of semi-solid slurry (a) with and (b) without EMS.
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C.K. Jin et al. / Journal of Materials Processing Technology 224 (2015) 156168
Fig. 16. Thin plate samples fabricated with different punch speeds (VP ) and friction states of cavity: (a) 30 mm/s, without lubricant; (b) 300 mm/s, graphite lubricant; and
(c) 30 mm/s, graphite lubricant.
C.K. Jin et al. / Journal of Materials Processing Technology 224 (2015) 156168
165
Fig. 16 illustrates a selection of the best thin plate samples fabricated under each condition. The thin plate samples were formed
at two punch speeds (30 and 300 mm/s) and cavity friction conditions (with and without the graphite lubricant). The black part on
the surface of the plate sample is the graphite lubricant. Fig. 16(a)
shows a sample formed at a punch speed of 300 mm/s without the
graphite lubricant in the cavity (mf = 0.9). Because semi-solid slurry
exhibits severe stickiness from its viscosity, the punch may get
stuck in the sleeve if the slurry is compressed without a lubricant.
Therefore, in this experiment, a small amount of graphite lubricant was sprayed within the die sleeve. The sample formed under
this condition had short shots at the sides of the end of the cavity. As shown by the simulation result for the pressure in Fig. 5(b),
this short shot can be attributed to the decreased pressure at the
entrance of the overow at the end of the cavity. Fig. 16(b) and (c)
shows the thin plate samples formed with a graphite lubricant in
the cavity (mf = 0.4) at punch speeds of 300 and 30 mm/s, respectively. The thin plate sample formed at a punch speed of 300 mm/s
with the graphite lubricant lled the cavity completely without
any short shots. Although only two overows were connected at
the end of the cavity, all ve overows were formed in the actual
experiment, and the entrance of the overow was broken and fell
off because of the ejection force from the sample being pulled out.
Forming at a punch speed of 30 mm/s led to a short shot at the end of
the cavity, and six overows resulted in short shots (Fig. 16(c)). As
shown by the simulation results for the lling temperature in Fig. 4,
this is the point where the materials temperature dropped below
585 C. Because the punch speed was 10 times less than the simulation condition, the temperature decreased even farther, which
may have caused incomplete forming.
Fig. 17 shows the thickness of the formed thin plate samples.
Groups A (A1, A2, and A3) and B (B1, B2, B3) indicate the centre
and side positions, respectively, of the sample. A1 and B1 (near the
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C.K. Jin et al. / Journal of Materials Processing Technology 224 (2015) 156168
gate) were thicker than A3 and B3 (near the overow), and group B
was thicker than group A. This was presumed to be due to shrinkage upon solidication. Fig. 18 shows the simulation results of the
solidication behaviour after lling. Similar to the lling patterns of
the semi-solid slurry, the solidication patterns in a contour shape
formed toward the gate at the overow. Because positions B1 and
A1 underwent solidication slowly compared to the other positions
in the cavity, they can be expected to be thicker. In contrast, B3 and
Fig. 19. Microstructure of thin plate samples fabricated with different punch speeds (VP ) and friction states of cavity: (a) 30 mm/s, without lubricant; (b) 300 mm/s, graphite
lubricant; and (c) 30 mm/s, graphite lubricant.
C.K. Jin et al. / Journal of Materials Processing Technology 224 (2015) 156168
167
Fig. 20. Volume fraction, equivalent diameter, and roundness of solid particles in
samples formed at 300 and 30 mm/s punch speeds with graphite lubricant.
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C.K. Jin et al. / Journal of Materials Processing Technology 224 (2015) 156168
under two friction conditions for the cavity and two punch speeds.
The effects of these parameters on the formability and mechanical
properties were analysed. The analytical and experimental results
are as follows:
(1) A fan-shaped gate allows the semi-solid slurry to evenly ll the
entire thin cavity.
(2) The increased ow rate along the cavitys sides can be controlled
by using overows located at the sides of the cavity.
(3) The placement of overows at the end of the cavity allows for
an even temperature and pressure (greater than atmospheric
pressure) distribution within the cavity.
(4) A semi-solid slurry having a solid fraction of 40% with ne
and globular solid particles can be obtained with an EMS. The
semi-solid without EMS had rosette particles and coarser globular -Al particles. The equivalent diameter and roundness
of the solid particles of the semi-solid slurry with EMS were
about 75 m and 1.5, respectively. Those of the solid particles of the semi-solid slurry with EMS were 110 m and 2.3,
respectively.
(5) The cavitys surface state experiences greater segregation
between the solid and liquid phases with increased friction.
When the friction of the cavity is high, solid particles nd it difcult to move into the cavity, so the liquid phase with relatively
good uidity ows into the cavity.
(6) A higher punch speed for compression of the semi-solid
slurry produces better formability for the thin plate and
a microstructure with densely and evenly distributed solid
particles.
(7) The microstructure of formed thin plate was ner and more
globular compared with the microstructure of the semi-solid
slurry with EMS. Plastic deformation of the solid particles
occurred by forced convection during lling. A small and globular grain structure then formed. The moving velocity and
distance of the solid phase increase for smaller and more globular grains.
(8) When the semi-solid slurry was formed at a punch speed of
300 mm/s with a graphite lubricant, a thin plate without segregation between the solid and liquid phases or other defects was
obtained with a tensile strength of 216 MPa and elongation of
10%.
Acknowledgements
This work was supported by the National Research Foundation of Korea (NRF) grant funded by the Korea government
(No. 2013R1A1A2062759). Ministry of knowledge Economy (No.
20104010100540), This study was also supported by the Korea
Research Foundation (KRF) grant funded by the Korea government
(MEST) (grant No. 2012-0001204).
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