1.

0 INTRODUCTION

Thixoforming, known as semi-solid metal (SSM) processing proposes several

advantages compared to liquid or solid processing. This process was patented by Spencer
during his PhD studies in the early 1970s. At that time, he was under the supervision of
Professor Flemings, who was one of the professor at the Massachusetts Institute of
Technology (MIT) (Mohammed et al., 2014). This procedure uses semisolid conduct and also
diminishes large scale isolation, porosity, and framing powers throughout the time of
moulding process. According to Salleh et al. (2013), a considerable measure of research work
has been done by different specialists with the end goal was to utilize the capability of this
procedure to create diverse items particularly for automotive industry.

These days, the thixoforming process has discovered manufacturing applications on

various applications because of its capacity to convey generation of top notch parts at costs
comparable to or lower than conventional forming techniques, such as casting or forging.
During the last 40 years of research efforts, a lot of different materials have been developed
and used with this process, the engine suspension mounts and steering knuckles for some
automobile brands are some examples for these application (Mohammed et al., 2013).

Thixoforming especially needs feedstock billet which arranged by extraordinary

technique since hardening step is basic contrasted with rheocasting. Thixoforming
additionally portrayed as close net shape framing because of billet warmed into strong fluid
temperature and incompletely dissolved non-dendritic slug into a metal die. Because of raw
material was not supplied widely, this process was considered high-cost manufacturing in
industry application. In fact, this technique offers more extensive scopes of plan alternative
which draw in individuals around there enhances it ceaselessly (Husain, Ahmad and Rashidi,
2017)

Atkinson and Ward (2008) has reviewed Flemings (1991) and found that
thixoforming is a process of shaping the metal alloys in the semi-solid state, which requires
that the alloys be treated so that they have a non-dendritic, spheroidal microstructure when
warmed to between the solidus and liquidus. According to Atkinson and Ward (2008), the
spheroidal semi-solid alloys are thixotropic, which have several methods to obtain the
spheroidal microstructrure, those are used electromagnetic (MHD) stirring (Pechiney A390
alloy) and casting followed by extrusion in the semi-solid state (Showa A390 alloy).

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 The expanding need of lighter and more secure autos is the main impetus behind
research in the territory of high quality light metal wellbeing part applications. This likewise
impacts drastically the innovative changes to the vehicle and has results for producers,
segment providers and gear makers. Salzburger Aluminum AG (SAG) in Lend, Austria has
been an able accomplice in aluminium forms. They has been on the cutting edge with regards
to presenting new advancements in smelting, casting and treating aluminium. The future
improvement of lightweight development (car and transport industry) depend particularly on
material properties of the utilized segments. The claim of better material properties with
synchronous weight lessening offers ascend to the improvement of innovatively propelled
throwing and shaping techniques. Horizontal continuous casting (HCC) and thixoforming
meet these prerequisites (Industrial Application of Thixoforming at SAG, 2006).

2.0 MATERIAL USED IN THIXOFORMING

SSM handling innovation has accomplished extensive progressions since its

disclosure in 1973. Just a couple of materials have been chosen for SSM preparing to deliver
business items for the most part in the car segment. In any case, there is a request to extend
the current aluminium composites for this procedure (Salleh et al., 2013). Salleh et al. (2013)
claims that Aluminium alloys is among the most prominent and well-known materials used in
the mechanical construction automotive industries with millions of aluminium alloy
components are produced every year through thixoforming processing route. There are
several commercial aluminium alloys such as A356, A357 and A390 were used as
thixoforming materials with provide high fluidity and good cast ability and usually used in
fabrication automobile components.

Hypereutectic alloys, for example, A390 (Al17Si4CuMg) and Al18SiCuNiMg show a

few extremely specific and intriguing properties, for example, high wear protection, high
quality and hardness, and low warm extension coefficients. Accordingly, they are utilized as a
part of substantial wear applications, frequently at raised or medium temperatures, for
example, in cylinders, barrel pieces and AC compressors (Kapranos et al., 2003).According
to Kapranos et al. (2003) also their utilization has dependably been disabled by a few

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difficulties, specifically their high inert warmth and ensuing long solidification time bringing
about pass on wear, difficulty in maintaining a strategic distance from isolation of huge
essential silicon particles, and for the most part their horrible shrinkage conduct. All of these
can be overcome by the thixoforming. By performing the thixoforming, the casting
temperature and heat content are very much reduced and homogeneously distributed primary
silicon is to be expected. Moreover, the shrinkage of a semi-solid material is significantly
reduced as compared with that of its liquid counterpart (Kapranos et al., 2003).

Kapranos et al. (2003) had performed an experiment using A390 Al-Si alloy as
starting material for the automotive part by modified the chemical composition of A390.
Various test examples were created in the three pieces: standard A390, A390 with 1%Ni, and
A390 with 4%Ni. The procedure of thixoforming for these A390 were shifted like injection
speed, fraction fluid, and soaking time in order identify the impact of these procedure
parameters on the nature of the final item. The end result shown that the additional 1% nickel
has better strength compared to the 4% nickel and the starting material. They found that the
rheological behaviour of A390 Al-Si alloy affected by the additional of 4% nickel. The
spheroidicity of the microstructure also decreased. These effects would reduce the strength of
the modified alloy compared with the original A390 aluminium alloy.

Atkinson and Ward (2008) claims that thixoforming can possibly make conceivable
the large scale manufacturing of aluminium high silicon piston with at first around 17% Si by
weight. This combination is less thick and has a lower warm extension co-proficient than
gravity pass on cast cylinders which depend on a composite with the eutectic silicon
substance of around 13%. They used two type of hypereutectic Al/Si alloys (magneto-hydro-
dynamically (MHD) stirred A390 from Pechiney and an extruded A390 alloy from Showa in
Japan) to form pistons by using thixoforming process.

The utilization of thixoforming innovation and its focal points for lightweight
structures parts is a primary motivation to utilize it for auxiliary components of entryways
(where the parts are replaced to sheet and castings) or other useful parts in cars. Industrial
Application of Thixoforming at SAG (2006) have the ability of their procedures by
conveying more than 34 unique parts for the new Audi A8 auto.

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 Figure 1: A-pillar for Audi A8 front door

Of every one of those parts, 13 are delivered in the thixoforming procedure. They
utilizes TX 630 alloy (AlSi7Mg0,3) which satisfies the popularity of their client needs for the
most part in the field of mechanical properties, great weldability, low porosity and thin
dimensional resistances. The need of lighter and more secure cars is the main basis behind
research in the zone of high quality light metal wellbeing part application. The new AUDI A6
will have two new thixoforming parts with high pliable compound write MAXXALLOY
TX540 for the pneumatic force vessel of the air suspension framework (Figure 2).

Figure 2: Air Suspension for Audi C6 – Top of the air tank

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3.0 SELECTION AND DETAILED DESCRIPTION OF THIXOFORMING
PROCESS.

The potential for forming processes based upon semi-solid metal alloys was first
recognised in the early 1970s. The microstructure of a suitable alloy comprises spheroidal
particles of solid surrounded by liquid phase of a lower melting point, rather than the
interlocking tree-like dendrites of conventionally cast alloy. It is this microstructure that gives
the material its thixotropic properties, i.e. when sheared the material flows, but when allowed
to stand, it thickens. Thixoforming is one member of a family of semi-solid forming
processes and it possesses characteristics of both casting and forging. The non-dendritic
feedstock necessary for thixoforming is usually produced using electromagnetic stirring in a
continuous casting process. The thixoforming process incorporates four operations :

 Firstly, a bar of thixoformable raw material is cut into appropriate slug lengths.
 Then the slugs are heated in a controlled manner, using either an induction coil or a
muffle furnace, into a uniform ‘mushy’ state.
 The heated slug is transferred to the shot sleeve of a suitably modified die casting
machine and injected into a die.
 The component feeder and gating systems are then removed using a clipping press or
band saw.

3.1 MOULD MATERIALS.

Thixoforming allows the use of softer, cheaper die materials due to the reduced
mechanical stresses acting on the die during filling and the lower alloy processing
temperature, e.g. for example, graphite, easily machinable stainless steels and disposable one
shot non-metallic dies have all been used. This permits the application of thixoforming to the
small production volumes required by rapid prototyping and mass customised production.

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3.2 ADVANTAGES OF THIXOFORMING.

The advantageous attributes of thixoforming have been described as follows:

 It is an energy efficient process which is easily automated and controlled to achieve

consistency
 Production rates are similar to pressure die casting or better
 Smooth filling of the die with no air entrapment and low shrinkage porosity gives
parts of high integrity.
 Lower processing temperatures reduce the thermal shock of the die, promote die life
and allow the processing of high melting point alloys (such as tool steels and stellites)
that are difficult to form by other means.
 Fine, uniform microstructures give enhanced component properties
 Weight savings can be achieved through optimised component design.

The high mechanical, geometric and surface quality of components produced through
thixoforming can justify the removal of additional production processes such as machining
steps and the need for reinforcing inserts. A simpler, more flexible production process
requires fewer resources for control and allows a more rapid response to changing customer
requirements.The extent to which these benefits are achieved depends upon the design of the
component and its dies, the optimisation of the processing conditions, the integration of the
technology into an existing production process and the demands of the organisation's
business environment. Not only are such benefits difficult to quantify in an analysis, but they
are also dependent upon managerial decisions.

4.0 DESIRED MICROSTRUCTURE AND PROPERTIES.

The characteristics of the thixoforming process allow savings to be made in many

other areas (e.g. removing machining operations, increased sales, reduced material use,
surface treatments, energy savings) and so will often offer economic benefits overall. The

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automotive component illustrated in figure 2 is an example where the near-net-shape,
mechanical integrity, high strength, optimum ductility and high volume of production
characteristics of thixoforming have enabled a cost effective design solution to be achieved.
The issue for potential industrial users is therefore to evaluate accurately the full extent of the
costs and benefits to be gained through implementing the technology. The difficulties in
achieving this arise from the reliability of predictions of future cash flows and evaluation of
what are often considered to' be ‘intangible’ benefits.

Identification of thixotropic properties The second part of the experimental work was
devoted to analysis of thixotropic properties. Thixotropy means time dependent fluid
behaviour in which the apparent viscosity decreases with time of shearing.The viscosity of
fluid usually recovers to initially value when shearing is stopped. The recovery process may
take place over a long time. The rotational viscometer can be used for identification of
thixotropy behaviour due to possibility of shear of the sample with constant rate during very
long time. Figure 5 shows the changes of viscosity of analysed aluminium alloy versus time
for different values of the shear rate. The basic rule indicates, that after increase of the shear
rate, the viscosity decreases over a time, what can be observed in Figure 5. When the shear
rate decreases one can observe an increase of the viscosity over a time. Before analysis of
thixotropy properties, the semisolid samples were sheared for some time to obtain globular
microstructures with rate of about 5 s-1

Figure 2. An example of a thixoformed automotive component.

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5.0 POSIBBLE DEFECTS, CAUSE AND REMEDIES.

Some commercial aluminum alloys are used as thixoform materials. This alloy offers
a high flow of flow and good durability and is commonly used in the manufacture of
automotive components. Forming alloys in semi-solid state requires approximately spherical
uniforms. The uniformly fine microstructure is dispersed in the matrix liquid when it enters
the die forming. If the microstructure is heated, grain boundaries begin to melt and there is
also a new secondary phase. The reduction is in internal energy, the structure will turn into a
Morphological sphere which benefits the partial solid processing.

Match with the ability to be round at high temperatures and to maintain lubricant
behavior during thixoforming promising candidates for semi-solid processing. Many stock
manufacturing processes provide a microbial structure Starting material; Examples of this
method are the cooling tendencies (CS), low superheat breaks (LSC) and magnetic stirrer
dynamic (MHD). Under this technique, MHD agitation is the most popular raw material
production method, as it can produce highly refined mouthpieces as well as enhances the
mechanical properties of thixoformed products

Structure that presents small grain size, low form factor (round), and the most
homogeneous and globular phase of the main phase has the best behavior in forming partial
solids as well as the best mechanical final properties that must determine the form factor.

6.0 CONCLUSION

In short, THIXOFORMING has become an industrial reality and field

Implementation of the process seems to be more apparent. Semi-solid partial properties Gel
(slurry) allows to obtain finite part with low wall thickness and without flaws.

The THIXOFORMING industry should focus on applications that really take

advantage of iRS Specifications and the rapid growth of aluminum usage in automotive,
military and aerospace The industry offers many possibilities. The basics of this new
technology require more determination.