Finite-element simulation of semi-solid metal processing of tool steel encased in carbon steel

The semi-solid metal processing allows for the production of components with complex geometries allied to lower forming forces. In the case of X210Cr12 tool steel, one big advantage of semi-solid metal processing is that it produces a microstructure free of precipitated chromium carbides, resulting in higher resistance to cyclic stresses. However, the application of this process in steels is limited until now due to technical difficulties, such as high temperatures, the necessity of a precise control of temperature, and the narrow liquidus–solidus range. For that reason, a preliminary numerical assessment of the forming procedure is highly welcome, in order to reduce potential errors in the final component. In this paper, we propose a methodology for the numerical simulation of semi-solid metal processing in steel samples under hot compression. We show that it is possible to use multilinear hardening plasticity models whose only input are the flow stress curves of each material. We also show that it is mandatory that these experimental curves are obtained through tensile tests performed at the same temperature as the working/simulated component. To validate the methodology, a full-scale experiment is undertaken so that the deformed sample can be compared to the numerical results. It is concluded that the methodology is suited for the assessment of mechanical quantities during the finite-element analysis of semi-solid processing of steel.