Today, tool life in high pressure die casting (HPDC) is of growing interest. A common agreement is that die life is primarily decided by the thermal load and temperature gradients in the die materials. Conformal cooling with the growth of additive ma...
Metal casting is an industrially important manufacturing process offering a superior combination of design flexibility, productivity and cost-effectiveness, but has limitations due to filling related defects. Several semisolid casting processes are a...
Semisolid casting of aluminium alloys is growing. For magnesium alloys, Thixomoulding became the dominant process around the world. For aluminium processing, the situation is different as semisolid processing of aluminium is more technically challeng...
Semisolid casting can provide excellent castings, but the nature of the pore-forming mechanisms has not been properly clarified. In the current communication, it was suggested that hydrogen precipitated during slurry making might have a decisive role...
Advanced processing techniques are required to produce functionally graded metal matrix composites due to the metallurgical conditions required during production. In this study, we developed a novel approach for this task by using a combination of tw...
Antifriction alloys such as AlSn20Cu are key material options for sliding bearings used in machinery. Uniform distribution and a near-equiaxed granularity tin phase are generally considered to be ideal characteristics of an AlSn20Cu antifriction allo...
In semi-solid metal high pressure die casting and in conventional high pressure die casting, it is common to find a defect band just below the surface of the component. The formation of these bands is not fully understood. However, there are several...
The semi-solid state casting procedure was used to manufacture as-cast AA5083, 1 and 2 wt.% of aluminosilicate reinforced composite material. After solidification, developed as-cast materials were subjected to shock wave treatment in the subsonic win...
The technology of casting with crystallization under pressure-squeeze casting belongs to unconventional pressure-casting methods. The melt or material in a semi-solid state is pressed under pressure until the casting solidifies completely. The input...
Al-7Si-0.5Mg aluminum alloy semi-solid slurry with good spherical grains was prepared by gas induced semi-solid process (GISS) and the effects of both holding time and medium alloy addition on the microstructure of the semi-solid slurry were investig...
Scroll compressors are popularly applied in air-conditioning systems. The conventional fabrication process causes gas and shrinkage porosity in the scroll. In this paper, the electromagnetic stirring (EMS)-based semisolid multicavity squeeze casting...
This study presents a new concept of refining and enhancing the properties of cast aluminum alloys by adding nanoparticles. In this work, the effect of adding alumina (Al2O3), titanium dioxide (TiO2) and zirconia (ZrO2) nano-particles (40 nm) to the...
The continuing quest for cost-effective and complex shaped aluminum castings with fewer defects for applications in the automotive industries has aroused the interest in rheological high pressure die casting (R-HPDC). A new machine, forced convection...
In this study, an enclosed cooling slope channel (ECSC) was used to produce a semi-solid slurry of the 7075 aluminum alloy. The effects of the pouring temperature and the rate of cooling water on the microstructure of the semi-solid slurry were studi...
There are multiple routes to prepare semi-solid slurries with a globular microstructure for semi-solid forming. The variations in the microstructure of semi-solid slurries prepared using different routes may lead to significant differences in the flo...
We investigated pore formation in aluminum foams by controlling primary crystal morphology using three master alloys. The first one was a direct chill cast A2024 (Al-Cu-Mg) alloy (DC-cast alloy). The others were A2024 alloys prepared to possess fine...
Semi-solid processes of aluminium alloys, characterised by the coexistence of solid and liquid phases, offer advantages in terms of mechanical properties and fatigue resistance, thanks to the more globular microstructure. Thermodynamic models can be...
Four-point bending fatigue tests were performed on semi-solid Al–7Si–Mg castings with varying magnesium contents and heat treatment conditions. Additionally, the effect of anodising on the fatigue resistance of semi-solid Al–7Si&nda...
The microstructure plays a key role in the mechanical properties of hyper-eutectic Al-Si alloys. In this study, we investigate the microstructural evolution of rheo-die-casting (RDC) on the Al-15Si-4Cu-0.5Mg alloy using a mechanical rotational barrel...
Semi-solid processing of alloys is nearing the end of its fifth decade in existence. This promising manufacturing route has undergone a number of changes over the past five decades and apart from certain successful industrial applications, it appeare...
Rare earth (RE) additions are capable of refining the α-Al phase as well as modifying the eutectic Si particles of alloys. The cooling rate in casting process should be carefully concerned when the Al-Si alloys are refined and modified by addin...
As-cast and semisolid casting using a cooling slope A356 alloy were processed by equal channel angular pressing (ECAP) for Si and grain refinement. The ECAP was conducted at room temperature in a mold, with a channel angle of 120°, and this resul...
This study prepared Al/steel composite plates with high shear strength using semi-solid cast-rolling (SSCR). The results indicate that the semi-solid diffusion effectively reduced the diffusion and reaction rate between Al and steel, thereby impeding...
AA6111 alloys are widely used in the automotive industry owing to their high strength/weight ratio, good corrosion resistance, and reasonable formability. During their manufacture through ingot metallurgy via direct chill (DC) casting, the alloys oft...
In this study, CNTs-reinforced Al-Cu-Mg-Si nanocomposites were successfully fabricated by high-energy ball milling (HEBM) combined with semi-solid stir casting. Then, the composites were subjected to hot extrusion. The Microstructure and Phase analys...
Metal matrix syntactic foams (MMSFs) are advanced lightweight materials constituted by a metallic matrix and a dispersion of hollow/porous fillers. Physical and mechanical properties can be fitted regarding matrix and filler properties and processing...
Semi-solid aluminium alloy processing (SSM) has advanced into a more mature process with many applications. The current paper aims to investigate the in-process behaviour of a production slurry using an engineering approach to estimate the properties...
In this paper, based on the as-cast CuSn10P1 alloy. Semi-solid CuSn10P1 alloy billet was prepared by cold-rolled isothermal treatment strain-induced melting activation (CRITSIMA). The effects of cold-rolling reduction, isothermal temperature, and iso...
Semi-solid ZCuSn10P1 alloy slurry was fabricated by a novel enclosed cooling slope channel (ECSC). The influence of pouring length of ECSC on the microstructures of ZCuSn10P1 alloy semi-solid slurry was studied with an optical microscope an optical m...
New Mg-3Zn-2Ca magnesium alloy was prepared using different processing techniques: gravity casting as well as squeeze casting in liquid and semisolid states. Materials were further thermally treated; thermal treatment of the gravity cast alloy was ad...
In situ Mg2Si–Al composites were prepared by using gravity casting and semi-solid extrusion. After P modification, the primary Mg2Si transformed to polygonal blocks. Extraction tests showed that the Mg2Si crystals had octahedral and tetrakaidek...
In the present work, Cu-Pb-Sn and Q235 laminated composite were fabricated by a horizontal semisolid rolling procedure. The interfacial structure, elemental distribution, and properties of the composite were investigated. Finite-element simulation wa...
In the light of increasing research into amorphous composites and their applications, as-cast specimens of multicomponent Ti48Zr18V12Cu5Be17 amorphous composites were prepared via water-cooled copper mold suction casting. Subsequently, the as-cast sp...
In order to solve the problem of insufficient convective heat transfer of uniaxial stirred melt, the temperature field and shear rate of melt under planetary stirring were studied based on CFD simulation. The microstructure and properties of this tec...
Research on corrosion resistance of cast aluminum alloys is reviewed in this article. The effect of the main microstructural features of cast aluminum alloys such as secondary dendrite arm spacing (SDAS), eutectic silicon morphology, grain size, macr...
This research investigated the rheo-die-casting process and the production of an A356/silicon carbide (SiC) composite by a thixoforming. The composite contained 15 percent by weight SiC particles of around 15–37 µm in size as the reinforc...
Magnesium and silicon concentrations in the interior of primary α-Al of Al-7Si-Mg alloys were studied at temperatures in the liquid-solid range and just after solidification was completed. Analysis of the results showed that the magnesium conce...
The solidification process in strip casting using a vertical-type high-speed twin-roll caster was clarified by inserting a 0.1 mm diameter K-type thermocouple into a strip during casting. The roll speeds of the copper rolls were 10 m/min and 30 m/min...
The distribution homogeneity of grain size affects the fluidity of the semi-solid slurry, which in turn affects the properties of the casting. One key factor affecting grain size uniformity resides in the nucleation number, which has been studied tho...
Semi-solid metal (SSM) processing has been an attractive method for manufacturing near-net-shape components with high integrity due to its distinct advantages over conventional forming technologies. SSM processing employs a mixture of solid phase and...
The A357-type (Al-Si-Mg) aluminum semi solid casting materials are known for their excellent strength and good ductility, which make them materials of choice, preferable in the manufacturing of automotive dynamic mechanical components. Semi-solid cas...
The main aim of this research was to investigate the aluminum AlSi9Cu3(Fe) machining chips recycling possibility utilizing a direct hot extrusion process and thixoforming. The thixo feedstock was prepared directly from the aluminum alloy AlSi9Cu3(Fe)...
Thermal conductivity is one of the most important thermophysical properties of a melt-cast explosive. However, the temperature-dependent thermal conductivity of such explosives cannot be easily measured across the whole solidification process (includ...
Rheo-forming is becoming the choice for production of high quality parts with diminished defects and fine integrity. In this paper, the novel self-inoculation rheo-diecasting (SIRD) process, in which semisolid slurry is produced by mixing two precurs...
Screw compressors are highly researched and developed prospects in industry because of their long service life, high transmission efficiency, low footprint and low vibration. As the key core part of the screw compressor, the screw is a typical, long-...
The thermal conductivity of alloys is gradually becoming appreciated. It is often assumed that heat treatment can improve the thermal conductivity of Al-Si-Mg-Cu alloys, but there has been little relevant research. This paper studies the effects of d...
The formation of hot tearing during direct chill casting of aluminum alloys, specifically AA6111, is a significant challenge in the production of ingots for industrial applications. This study investigates the role of hydrostatic pressure and tensile...
Improving the engineering properties of A356 alloy is an appealing option for the automotive industry. This study aimed at refining and redistributing Si particles and the eutectic phase by applying T6 heat treatment to a semi-solid A356 alloy, follo...
This article provides an overview of high-pressure die casting (HPDC)-related research undertaken at the EPSRC Future LiME Hub between 2015–2022. The project aimed to identify the cause of variability in the tensile ductility of die-cast struct...
The rise of metal additive manufacturing technology has increased the demand for high-performance alloys such as metal matrix composites (MMCs). The metallurgical production of MMCs remains a challenge. The nano-powder of dielectric particles does no...
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