Thixoforming of an aluminum component with a die designed by process simulation

A die design to fabricate a near net shape scroll component using semi-solid-aluminum alloys is performed by the finite element method (FEM). In the case of medium and high volume fractions of solid, the distribution of strain rate is calculated by using compression test data of semi-solid materials (SSMs). By using the computational results, the overflow position to obtain a homogeneous strain rate in die design process is proposed. The effect of the overflow position in die design parameters on liquid segregation in the thixoforming process has been theoretically investigated to manufacture the scroll component with good mechanical properties. Thixoforming experiments with the designed die are carried out successfully. The die filling patterns of SSM for variation of die temperature and pressing force have been investigated. The hardness of the thixoformed scroll products is evaluated in terms of the microstructure for each position.