Effect of rheocast and thixocast characteristics of eutectic Lead–Tin alloy sheet on deep drawing

Semisolid metal processing is a relatively new technology in metal forming. It is different from conventional metal forming technology, which use either solid metals or liquid metals as starting material. Semisolid metal processing deals with semisolid slurries in which non-dendritic solid particles are dispersed in a liquid matrix. This work involves the developing of an alloy sheet blank with a structure, which is non-dendritic, irregularly spherical solid solution by rheocasting and thixocasting techniques. This alloy sheet blank was used to form simple cup by deep drawing process. The formability of this alloy, reduction in applied load, strength of the alloy and the surface strain parameters were studied using Erichsen cupping test, tensile test and grid marking the blank surface. The above parameters were compared for each of these casting processes and the effective method of processing was identified. Thixocast components were found to have good qualities than the conventionally cast and rheocast components.