• Transactions of Materials Processing
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• v.14 no.4 s.76
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• pp.351-359
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• 2005

The semi-solid processing is now becoming of great interest for the production of various parts by pressure die casting. Also, the rheo-casting has been substituted for thixo-casting, because the rheo-casting can control the solid particles to globular and non-dendritic solid phase. In the rheo-casting process, the important thing is to control the solid particles behavior in semi-solid materials. So in this paper, to control solid particles behavior in semi-solid materials, we experimented about the die filling tests during the semi-solid die casting in 0.3, 0.4, 0.5 and 0, 6 solid fraction. The die filling in semi-solid die casting were simulated by MAGMA soft/thixo module. By the die filling tests and computer simulation, the effect of solid particles behavior in rheology flow had been investigated.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.664-667
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• 2004

The semi-solid processing is now becoming of great interest for the production of various parts by pressure die casting. Also, the rheolory casting has been substituted for thixo casting, because the rheology casting can control the solid particles to globular and non-dendritic solid phase. In the rheology casting process, the important thing is to control the solid particles behavior in semi-solid materials. So in this paper, to control solid particles behavior in semi-solid materials, we experimented about the die filling during the semi-solid die casting in 0.3, 0.4, 0.5, 0,6 solid fraction. The die filling in semi-solid die casting were simulated by MAGMAsoft/thixo module. By the die filling tests and computer simulation, the effect of solid particles behavior in rheology flow had been investigated.

• Transactions of Materials Processing
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• v.11 no.4
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• pp.312-322
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• 2002

In this study, an innovative semi-solid die casting technology to replace heavier cast iron compressor parts with lightweight aluminum castings was proposed, and the application possibility for home-appliance component was investigated. The most important factors regarding the semi-solid die casting process are the reheating process of the raw materials to the semi-solid state, specifications of the forming machine, the optimal injection conditions and die design. Materials used in this study were A3S7 and hSn alloys fabricated by the electromagnetic stirring process. The optimal injection conditions for semi-solid die casting process were Presented with the reheating conditions of the semi-solid materials. To investigate the effect of plunger tip shape on the formability and mechanical properties in semi-solid die casting process for complicated shape part, two kinds of plunger tip shape with long and short plunger tip taper are proposed.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.06a
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• pp.135-147
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• 1997

The production of light metal parts using aluminum is mainly performed by die casting and squeeze casting, which directly fabricate the required shape from the liquid state. However, die casting is subject to defects such as shrinkage porosity and air trapped when molten metal enters the cavity, whilst squeeze casting also has defects due to turbulent flow in the die cavity. Both diecasting and sqeeze casting have inhomogeneous mechanical property in terms of dendritic structure during solidification. Active research has been carried out on semi-solid processing, rather than on conventional process methods such as die casting, which involve various problems. Therefore in this paper, to introduce the fundamental technology for d e design, in die casting and forging process with semi-solid materials, relationship between stress and strain of semi-solid materials, and for producing parts die design has been proposed as parameters of globulization of the microstructure and gate shape. The prevention of various defects to produce sound parts are also introduced.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.60-63
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• 2003

Semi-solid forming is the process of stirring alloy during solidification, making the mixture of liquid and solid, solidifying it, reheating it to the solid-liquid coexistent temperature, and then injecting this semi solid slurry into dies. In the semi-solid die casting process, it is very important to find out the correlation of injection condition, microstructure and mechanical properties. Especially, an improper injection condition is the main cause of liquid segregation and non-homogeneous mechanical properties due to the difference of solid fraction according to the position of the products. To ensure the database requisite to the semi-solid die casting product, it is essential to acquire the mechanical properties considering liquid segregation to the injection condition. In this study, the effect of injection condition on liquid segregation, formability, microstructure and mechanical properties in a thin product was investigated.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.10a
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• pp.261-264
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• 2003

Semi-solid processing is now becoming of great interest for the production of various parts by pressure die casting. Many advantages are associated with this forming process at the condition that the forming operation is performed under appropriate conditions. The thixoforming process, which needs a suspension of a globular, non-dendritic solid phase in the liquid phase, is characterized by three major steps. The first step is casting of billets with a microstructure suited for thixoforming. The second step is reheating of slugs cut from these billets. The third step is injection of the semi-solid slugs into a die. In this paper, the horizontal reheating machine to obtain the optimal conditions suitable for semiu-solid die casting process was used and applied to extrusion material. It is estimated the possibility of application on semi-solid die casting with extrusion material through various results.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.05a
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• pp.120-123
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• 2001

The semi-solid casting will have a higher internal integrity, mechanical properties and dimensional accuracy than the conventional castings. This process can reduce the manufacturing costs and finished weight for critical components. The semi-solid casting are capable of greater dimensional repeatbility, this supplies considerable savings when extensive machining, salvage and scrap are key variables in the current automotive product. One of the most important factor regarding the semi-solid die casting process are the reheating method of the raw materials to the semi-solid state. Therefore, in this present work, the horizontal type induction heating system to obtain the optimal reheating conditions suitable for semi-solid die casting process was designed and manufactured. And the microstructure of reheated materials was investigated.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.70-73
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• 2003

Semi-solid processing is now becoming of great interest for the production of various parts by pressure die casting. Many advantages are associated with this forming process at the condition that the forming operation is performed under appropriate conditions in terms of alloy microstructure, injection velocity and pressure. In this study, to look into the relation along them, the experiment of semi-solid die casting has been peformed with various condition of injection, and investigated their microstrucure and solid fraction

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.131-134
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• 2007

A semi-solid forming technology has a lot of advantages compared to the die casting, squeeze casting and hot/cold forging, so semi-solid forming has been studied actively. Semi-solid forming has two methods. One is thixoforming with reheating of prepared billet, the other is rheoforming with cooled melt until semi-solid state. Thixoforging technology can produce non-dendritic alloys for semi-solid forming complex shaped parts in metal alloys. In this study, the thixoforging was experimented with made rheology materials by the spiral stirrer equipment. Rheology materials for forging were made by A356 casting aluminum alloy and A6061 wrought aluminum alloy. After experiment, forged samples were measured microstructure and were heat treated for high mechanical properties.

• Transactions of Materials Processing
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• v.14 no.1 s.73
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• pp.49-56
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• 2005

In the semi-solid die casting process, an important thing is the flow behavior of semi-solid materials. The flow patterns of the semi-solid material can make the defects during die filling. To control the flow patterns is very important and difficult. In this paper, the flow behavior of the semi-solid A356 alloy material during die filing at various die gate shapes has been observed with the grain size controlled material. The effect of the gate shape on the die filling characteristics was investigated. The filling tests in each plunger stroke were experimented, and also simulated on the semi-solid material die casting process by MAGMAsoft. According to the filling tests and computer simulation, the effect of the gate shape on liquid segregation has been investigated.