Forging of liquid and partially solid Sn-15 Pct Pb and aluminum alloys
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DUCTION F U N D A M E N T A L and a p p l i e d r e s e a r c h in the p a s t five y e a r s h a s l e d to the finding that c e r t a i n m e t a l f o r m i n g o p e r a t i o n s can be c a r r i e d out u s i n g a p a r t i a l l y s o l i d c h a r g e m a t e r i a l p r o v i d e d the s o l i d p r e s e n t i s p a r t i c u l a t e and s p h e r o i d a l in s h a p e . ~-5 In the w o r k p r e s e n t e d h e r e , the p o s s i b i l i t y of e x p l o i t i n g the s p e c i a l m e t a l l u r g i c a l s t r u c t u r e and r h e o l o g i c a l b e h a v i o r of a p a r t i a l l y s o l i d i f i e d a l l o y in a f o r g i n g - t y p e o p e r a t i o n was i n v e s t i g a t e d , and the r e s u l t s w e r e c o m p a r e d to c o n v e n t i o n a l liquid m e t a l f o r g i n g . T h e e f f e c t of p r o c e s s v a r i a b l e s d u r i n g f o r g i n g of both liquid and p a r t i a l l y s o l i d a l u m i n u m a l l o y s on the s t r u c t u r e and p r o p e r t i e s of c o m p o n e n t s p r o d u c e d and on the die t h e r m a l b e h a v i o r was s t u d i e d . C o m p u t e r s i m u l a t i o n w o r k on h e a t flow was c a r r i e d out to d e t e r m i n e the e f f e c t of a p p l i e d p r e s s u r e d u r i n g the f o r g i n g o p e r a t i o n on the h e a t t r a n s f e r c o e f f i c i e n t at the d i e - m e t a l i n t e r face. Shaping of liquid m e t a l s by f o r g i n g - t y p e o p e r a t i o n s h a s b e e n d e s c r i b e d under a v a r i e t y of n a m e s s u c h a s s q u e e z e c a s t i n g , liquid m e t a l f o r g i n g , e x t r u s i o n c a s t ing and liquid s t a m p i n g . The b a s i c p r o c e s s s t e p s a r e a s f o l l o w s . A m e a s u r e d a m o u n t of liquid m e t a l is p o u r e d into the l o w e r c a v i t y of an open d i e s e t . A f t e r p a r t i a l s o l i d i f i c a t i o n of the o u t e r e x t r e m i t y of the c h a r g e , the two die h a l v e s a r e b r o u g h t t o g e t h e r to f o r m the p a r t . S o l i d i f i c a t i o n is then c o m p l e t e d u n d e r a p r e d e t e r m i n e d h y d r o s t a t i c p r e s s u r e . W h i l e the p r o c e s s is r e l a t i v e l y new in the U.S.A., it had b e e n e x S. D. E. RAMAT1 and G. J. ABBASCHIAN are Graduate Student and Visiting Associate Professor, respectively, in the Department of Metallurgy and Mining Engineering: D. G. BACKMAN is Assistant Professor in the Department of Mechanical and Industrial Engineering and R. MEHRABIAN is Associate Professor in the Departments of Metallurgy and Mining Engineering and Mechanical and Industrial Engineering, University of Illinois, Urbana, IL 61801. Manuscript submitted August 10, 1977. METALLURGICAL TRANSACTIONS B
t e n s i v e l y i n v e s t i g a t e d and u s e d in the U.S.S.R. and to a l e s s e r d e g r e e in J a p a n . V a r i o u s i n v e s t i g a t o r s have r e p o r t e d s u b s t a n t i a l i m p r o v e m e n t s in m i c r o s t r u c t u r e ( e . g .
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