David J. Browne

Mechanical stir casting of aluminium alloys from the mushy state: process, microstructure and mechanical properties

Abstract A comprehensive study was carried out to establish the effects of controlled stirring during solidification on the microstructure and mechanical properties of aluminium alloys, in comparison to conventionally gravity chill cast material. A novel device comprising a grooved reaction bonded silicon nitride rod rotating in a tube-like crucible was used to process aluminium alloys in the mushy state. The stir casting device was specially designed to also enable rheometric study of the alloys in this condition. A factorial design of experiments was used to determine the effect of the process variables shear rate ( γ ), shear time (ts), and volume fraction solid during shear (fs) on microstructure and both static and dynamic mechanical properties of the stir cast alloy. Investigation of the microstructure consisted of computer-aided image analysis of the primary phase morphology. A more globular primary phase was achieved at low values of fs, but this was not the optimum morphology for mechanical properties. In all cases, improved mechanical properties and reduced porosity were obtained in the stir cast condition in comparison with conventional casting and in comparison with previous work on stir casting. Comparison with alloy commercially rheocast via electromagnetic stirring, however, showed that the latter had superior mechanical properties. It is proposed that the mechanical stir casting process be considered as an alternative to gravity die casting in cases where very simple and thick walled shapes are required.

A FIXED GRID FRONT-TRACKING MODEL OF THE GROWTH OF A COLUMNAR FRONT AND AN EQUIAXED GRAIN DURING SOLIDIFICATION OF AN ALLOY

In a new model of alloy solidification in a square mold, the interface being followed by a front-tracking technique is representative of a curve joining the tips of growing solid dendrites. The coupled heat equation is solved via an Eulerian control-volume formulation. In the absence of convection, the nucleation and nonequilibrium growth of both a front of columnar grains and a single equiaxed grain have been modeled and animated. This is a major step toward the computationally efficient complete direct numerical simulation of the developing grain structure in a casting process.

Use of experiment and an inverse method to study interface heat transfer during solidification in the investment casting process

Abstract A technique to determine the thermal boundary conditions existing during the solidification of metallic alloys in the investment casting process is presented. Quantitative information about these conditions is needed so that numerical models of heat transfer in this process produce accurate results. In particular, the variation of the boundary conditions both spatially and temporally must be known. The method used involves the application of a new inverse heat conduction method to thermal data recorded during laboratory experiments of aluminium alloy solidification in investment casting shell moulds. The resultant heat transfer coefficient for the alloy/mould interface is calculated. An experimental programme to determine requisite mould thermal properties was also undertaken. It was observed that there is significant variation of the alloy/mould heat transfer coefficient during solidification. It is found to be highly dependent on the alloy type and on the vertical position below the initial free surface of the liquid metal. The aluminium casting alloys used in this study were 413, A356, 319 (Aluminum Association designations), and commercially pure aluminium. These alloys have significantly different freezing ranges. In particular, it was found that alloys with a high freezing range solidify with rates of heat transfer to the mould which are very sensitive to metallostatic head.

A review of the processing, composition and temperature-dependent mechanical and thermal properties of dielectric technical ceramics

The current review uses the material requirements of a new space propulsion device, the Variable Specific Impulse Magnetoplasma Rocket (VASIMR®) as a basis for presenting the temperature-dependent properties of a range of dielectric ceramics, but data presented could be used in the engineering design of any ceramic component with complementary material requirements. A material is required for the gas containment tube (GCT) of VASIMR® to allow it to operate at higher power levels. The GCT’s operating conditions place severe constraints on the choice of material. An electrically-insulating material is required with a high-thermal conductivity, low-dielectric loss factor, and high-thermal shock resistance. There is a lack of a representative set of temperature-dependent material property data for materials considered for this application and these are required for accurate thermo-structural modelling. This modelling would facilitate the selection of an optimum material for this component. The goal of this article is to determine the best material property data values for use in the materials selection and design of such components. A review of both experimentally and theoretically determined temperature-dependent and room temperature properties of several materials has been undertaken. Data extracted are presented by property. Properties reviewed are density, Young’s, bulk and shear moduli, Poisson’s ratio, tensile, flexural and compressive strength, thermal conductivity, specific heat capacity, thermal expansion coefficient, and the factors affecting maximum service temperature. Materials reviewed are alumina, aluminium nitride, beryllia, fused quartz, sialon, and silicon nitride.

Replication of micro/nano-scale features by micro injection molding with a bulk metallic glass mold insert

The development of MEMS and microsystems needs a reliable mass production process to fabricate micro components with micro/nano-scale features. In our study, we used the micro injection molding process to replicate micro/nano-scale channels and ridges from a bulk metallic glass (BMG) cavity insert. High-density polyethylene was used as the molding material and the design of experiment approach was adopted to systematically and statistically investigate the relationship between machine parameters, real process conditions and replication quality. The peak cavity pressure and temperature were selected as process characteristic values to describe the real process conditions that the material experienced during the filling process. The experiments revealed that the replication of ridges, including feature edge, profile and filling height, was sensitive to the flow direction; cavity pressure and temperature both increased with holding pressure and mold temperature; replication quality can be improved by increasing cavity pressure and temperature within a certain range. The replication quality of micro/nano features is tightly related to the thermomechanical history of material experienced during the molding process. In addition, the longevity and roughness of the BMG insert were also evaluated based on the number of injection molding cycles.

Experimental investigation of the transient and steady state rheological behaviour of Al–Si alloys in the mushy state

Abstract In order to properly model and control the semi-solid processing of metallic alloys, their thixotropic behaviour requires proper characterisation. In particular, the effects of shear rate, shear time, temperature and rest time on the rheology of such slurries needs to be understood and quantified. A purpose-built high temperature Searle rheometer was used to determine the rheological behaviour of aluminium alloy slurries at shear rates from 3.1 to 124.8 s −1 , periods of shear of up to 60 min for each shear rate, and periods of rest (no stirring) of up to 60 min for Al–4wt.%Si and A356 alloys. Continuous cooling rheometry was used to determine the coherency point of the alloys. Isothermal fractions solid of 0.36 for Al–4%Si and 0.33 for A356 were investigated. Isothermal tests were used to follow the temporal evolution of viscosity, which was found to be significantly different for both alloys, particularly at low shear rates. Steady state viscosity values that were determined over a range of shear rates indicated severe pseudoplastic behaviour, as measured by a viscosity–shear rate power law index less than −1. This work confirms that this finding is an actual rheological feature and not an artefact of a particular measurement device. A study using shear rate jumps determined the isostructural behaviour of the alloys by discounting equipment inertial effects. It is shown that peak stress or apparent viscosity is a better indicator of slurry thixotropy than the hysteresis loop from shear ramping experiments, and the work also shows that the effect of agglomeration on fluidity is an important parameter to measure as it has consequences for thixoforming.

OPTIMISATION OF ALUMINIUM SHEET FORMING USING A FLEXIBLE DIE

Abstract This paper presents an experimental study of the rubber-pad forming process, which is used widely to produce aerospace and automotive parts, and in other industries which produce sheet metal components. The forming of thin sheet shallow shapes is the most frequent application. The process has a number of advantages over conventional processes: only one rigid tool half is required to form a part; parts with excellent surface finish can be formed as no surface tool marks are created; thinning of the workpiece is reduced considerably; and different metals, of various thicknesses, can be formed using the same tooling. Significant quality improvements for a range of alloys have been demonstrated. The present paper describes the process and the results of work carried out to investigate the capability of the process and to optimise the process parameters to ensure a defect-free product. The experimental investigation was done using a 100 t double-acting hydraulic press to produce a part based on the design of a support rib for an aircraft wing or tail flap. A PC was interfaced with the machine for monitoring, data logging and analytical purposes.

Towards nano-injection molding

Bulk metallic glasses (BMGs), having no limiting microstructure, can be machined or thermoplastically-formed with sub-micron precision while still retaining often-desirable metallic properties such as high compressive strength. These novel materials thus have enormous potential for use as multi-scale tools for high-volume manufacturing of polymeric MEMS and information storage devices. Here we show the manufacture of a prototype BMG injection molding tool capable of producing centimeter long polymeric components, with sub-micron surface features.

Direct thermal method: new process for development of globular alloy microstructure

Semisolid metal processing (SSMP) is of growing industrial significance particularly for magnesium and aluminium alloys. SSMP requires a binary micro-structure in which the primary phase is approaching a spheroidal (globular or non-dendritic) shape. Traditionally this is achieved by stirring the alloy in the mushy state. An alternative method, which is gaining popularity, is the so-called slurry-on-demand or new rheocasting process in which solidification conditions are controlled via active thermal management to yield non-dendritic solid in a liquid matrix. The authors present here a novel low-cost process, the direct thermal method (DTM), in which a globular microstructure, suitable for SSMP, is achieved via the naturally occurring thermal environment in a very simple casting experiment. Basically the DTM is a process in which liquid alloy of low superheat is poured into a cylindrical metallic mould of very low thermal mass but high thermal conductivity. Heat-matching between alloy and mould results in a pseudo-isothermal hold within the solidification range of the alloy, made possible by the very low rate of heat loss to the environment. Without the use of any special insulation or heating devices, the fraction solid during the experiment and the hold time can be modified by simple alterations to the process variables and geometry. The thin mould walls also make quenching easy. The resultant alloy morphology is characterised for an aluminium alloy designation A356. IJCMR/463

Bulk Metallic Glasses for Implantable Medical Devices and Surgical Tools

With increasing knowledge of the materials science of bulk metallic glasses (BMGs) and improvements in their properties and processing, they have started to become candidate materials for biomedical devices. A dichotomy in the types of medical applications has also emerged, in which some families of BMGs are being developed for permanent devices whilst another family - of Mg-based alloys - is showing promise in bioabsorbable implants. The current status of these metallurgical and technological developments is summarized.