Optimization of the process parameters and tooling improvement for the rheocasting of high quality aluminum components using the SEED process

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Proceedings titleProceedings. Shape Casting: 4th International Symposium 2011 in honor of Prof. John T. Berry
ConferenceTMS 2011 Annual Meeting & Exhibition - Shape casting Symposium, San Diego, California, USA, February 27, 2011
Pages273281; # of pages: 9
SubjectProcess parameters; rheocasting; aluminum components; Paramètres du processus; Amélioration; outillage; rhéomoulage; composants; aluminium; tooling improvement; SEED process; procédé SEED
AbstractThe automotive industry has leaned greatly towards the use of aluminum alloys by virtue of their strength and low density. Given this, the potential for aluminum use in the fabrication of vehicle parts has greatly increased. However, there are limited studies devoted to the improvement of the casting process. In the present work, the SEED (Swirled Enthalpy Equilibrium Device) rheocasting method, as developed by Rio Tinto Alcan in collaboration with the Aluminium Technology Center of NRC Canada (ATC-NRC), was analyzed by the authors in an attempt to optimize operating parameters (e.g. proper mold filling, slurry temperature, injection speed, etc.), which affect the final cast part quality. In many of the existing semi-solid casting processes which use billets as feedstock, for example, it is often found that the outer surface of the billets is contaminated. During the injection phase, a billet's external skin comes into contact with air and lubricant, and, as a result, becomes contaminated. The use of such a contaminated billet can often result in an increased rejection rate of cast parts. The SEED process, which uses heat extraction of the liquid aluminum alloy via mechanical agitation (swirling) in a confined cylinder to form the semi-solid billet on site, has already proven successful in producing sound aluminum castings having an excellent combination of strength and ductility. The resulting semi-solid billet, having a microstructure consisting of α-Al globules surrounded by the eutectic phase, is then injected into the cold chamber of an HPDC machine.
Publication date
PublisherJohn Wiley and Sons, Inc.
AffiliationNational Research Council Canada; NRC Industrial Materials Institute
Peer reviewedNo
NRC number53435
NPARC number17104543
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Record identifiercdeeddb3-9219-48a7-b140-b6854c7776fe
Record created2011-03-18
Record modified2016-05-09
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