Metal forming operations are among the most costly materials processing steps that require large capital investments and are extremely energy intensive. A technique called semi-solid forming is an attractive process but the cost of preparation of semi solid alloys is relatively high, due to the expense associated with electromagnetic or mechanical stirring of the liquid alloy during solidification. The principle objective of this project is to develop a new, less expensive, energy efficient process for producing alloys (such as semi-solid aluminum alloys for automotive applications), which can be heated to a semi-solid state, transformed and effectively formed into parts which meet or exceed the existing structural and mechanical strength characteristics of semi-solid forming. Phase I of the project will concentrate on traditional aluminum silicon alloys 356 and 357 which are currently being produced for semi-solid forming by electromagnetic stirring. Formability studies will be performed to determine if combinations of configuration, injection temperature and pressure will allow ease of formation and acceptable final properties. These results will be compared to companion experiments using electromagnetically stirred ingot.
Commercial Applications and Other Benefits as described by the awardee:The principle benefit of a successful research effort would be reduced cost semi-solid formable aluminum alloys. These are produced exclusively by semi-solid thermal treatment, which permit economical replacement of heavier cast iron and steel parts, particularly in automotive applications, resulting in reduced energy consumption both in raw material formation and vehicle fuel consumption.
