December 3, 2018


The rheocasting is a process of creating a semi-solid slurry followed by its pushing into a metal mold for freezing. In thixocasting, the slurry freezes to fully solid. is focusing on reducing the porosity content of conventional die castings. Key Words. Semi-solid casting, thixocasting, rheocasting, aluminum alloys. 24 Feb Rheocasting. 1. Seminar Report On Study Of Rheocasting Under Guidance of- Dr . Amitesh Kumar Presented By- Satyaranjan pattanayak; 2.

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Within the framework of foundry technologies the presence of defects, anomalies and imperfections in the final product are an ever present reality. Author links open overlay panel M. Thixocasting billets are sold at a premium price, up to twice the ingot-alloy price, and cannot be reused by the die-caster.

In addition, a process which at present is only used for magnesium rheocassting thixomoldinginvolves loading alloy chips into a heated Archimedes?

Because of this the process can be applied to rapid prototyping needs and mass production. Neelameggham, in Fundamentals of Magnesium Alloy Metallurgy The key to doing this successfully is thermal management of the runner system and the die cavity.


Semi-solid casting is a casting process that rhelcasting filling a mold with the metal rheocazting a partially molten state in which globules of solid are homogeneously dispersed in the liquid.

The alternative approach is to allow a rheocast billet to solidify fully, to cut it up into slugs of appropriate size, which are heated back to the semisolid condition when required at a later date. Abstract This paper reviews what we know, and what we do not know, about the rheology of semi-solid metals, eheocasting about practical, metal-forming processes Rheocasting Processes which utilize semi-solid metals.

In addition, the more uniform distribution of the SiC pobserved in the composites produced by the rheocasting process, delays the grain growth.

Compocasting, or rheocastingsuggested by Mehrabian et al. For aluminum alloys, typical parts include engine mounts, air manifold sensor harnesses, engine blocks, and oil pump filter housings.

Comparison of microstructures resulting from various casting processes courtesy Ube Machinery, Inc. Neelameggham, in Fundamentals of Magnesium Alloy Metallurgy1. In some liquid processing techniques, such as rheocastingthis can be attributed to the presence of broken dendrite arms as a result of stirring the melt in the semi-solid rheocastijg.


Get Access Get Access. A mixture is contained in a crucible with an rheocastnig at the bottom used to pour out the mixture for further processing. Rneocasting casting process Figure 2: Unlike thixocasting, which re-heats a billet, rheocasting develops the semi-solid slurry from the molten metal produced in a typical die casting furnace. A yet third process was developed under the umbrella of semi-solid forming, called thixomolding, and has gained greater use for magnesium compared with the other two processes, which are used primarily for aluminum.

Over time, as die thermal management techniques evolve, it is expected that the advantages of thixomolding will extend to automotive components.

In the late s and early s processes were developed to make salt-coated magnesium which can be made from molten metal Legge et al. The particular distribution and volume fractions of the two phases render the material thixotropic, where its viscosity decreases with shear rate, to enable the mixture to be injected at high rates into a die cavity while maintaining laminar flow.

Such atomization requires protective gas use during the atomization to minimize burning. Thixocasting has the ability to produce extremely high quality components due to the product consistency that results from using pre-cast billet that is manufactured under the same ideal continuous processing conditions that are employed to make forging or rolling stock.

Semi-solid metal casting

Primary production of magnesium R. The Figures 1 and 2 present the schematic overview of rheocazting casting process and microstructure of rheocast A alloy.

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Magnesium alloys for lightweight powertrains and automotive structures B. As it nears the solidus temperature the grains recrystallize to form a fine grain structure. The misfit strains, introduced by the difference in coefficient of thermal expansion between SiC particulates and matrix, are reduced when porosity is present at the interface between the reinforcements and the matrix.


The Rheo Casting Process | Total Materia Blog

Upon reheating, the billet is ready to be placed into the shot sleeve of an HPDC-like machine and injected into the die cavity. At the present time, there is insufficient production experience to determine the extent to which the practical advantages of the process can be translated rheocawting economic and technical gains in the marketplace.

Our fundamental understanding of the mechanisms of formation and deformation of these slurries is as yet limited.

The screw drives the chips down the barrel under heating and shearing conditions, which generate good semisolid material, and then forces the slurry into a die in an operation similar to plastic injection rhheocasting. Similar results were obtained by minimizing the SiC particulates-associated porosity, as this can be achieved by the rheocasting process.

Rheocasting – ScienceDirect

Due to the fact that rheological properties of semi solid alloy are a function of f sonly some alloys with clearly defined eutectic point and f sis not a strong function of temperature in the working f s range rheocssting suitable for SSP rheocastiing good control of temperature is also required.

Generally, interdendritic shrinkage pores, inclusions, secondary dendrite arm spacing are privileged crack initiation sites, independently of the loading conditions. In the thixocasting route, a billet containing globular microstructure is prepared rehocasting a billet manufacturer. The benefits of semi-solid casting are: Obviously, a matrix characterized by a large difference between solidus and liquidus temperatures makes easier to process the composites, especially at the final step.

The process later evolved into thixocasting, where carefully prepared electromagnetically stirred billets that contain globular alpha rheocsating are dispersed within a lower melting point eutectic phase. Molten magnesium can be atomized to making fine spherical shape powder which was adopted for pyrotechnics and military applications. In addition to the use of granular magnesium as a chemical reactant, magnesium alloy powders have been formed into structural near net shapes by unique powder metallurgical processing such as thixo-molding or rheocasting.