A novel semi-solid die forging process for the 6061-aluminum rim support disc was proposed and investigated. An improved constitutive model was established based on the Arrhenius-type equation by integrating a hyperbolic sine function and a term representing the liquid phase fraction. With the improved constitutive model, the predictive error of peak stress was reduced from 15.45% to 5.51%. The L16 (41 × 31 × 31) orthogonal experimental design was employed to explore the influence of billet temperature, mold temperature, and die speed on key indicators including the forming force, effective stress and effective strain. Optimum process parameters were determined as a billet temperature of 630°C, a mold temperature of 300°C, and a primary die speed of 75 mm/s. Experimental validation was conducted under these optimum process parameters, resulting in sufficient cavity filling and refined microstructures with an average grain size of 68 μm. The maximum forming load was reduced by 83% to 116t, while maintaining the tensile strength and elongation still within requirements.
ZhangWXuJ.Advanced lightweight materials for automobiles: a review. Mater Des2022; 221: 110994.
2.
ZhangJLinGVaidyaU, et al. Past, present and future prospective of global carbon fibre composite developments and applications. Compos B Eng2023; 250: 110463.
3.
TaubADe MoorELuoA, et al. Materials for automotive lightweighting. In: ClarkeDR (ed.) Annual review of materials research, vol. 49. pp.327–359. Cham: Springer.
4.
PapaIPanicoMCarandenteM, et al. Innovative joining technologies for lightweight material vehicles. Proc IMechE, Part C: J Mechanical Engineering Science2024; 238(12), 5674–5684.
5.
ZhangMSTianYQZhengXP, et al. Research progress on multi-component alloying and heat treatment of high strength and toughness Al-Si-Cu-Mg cast aluminum alloys. Materials2023; 16(3): 1065.
6.
OmiyaleBOOlugbadeTOAbioyeTE, et al. Wire arc additive manufacturing of aluminium alloys for aerospace and automotive applications: a review. Mater Sci Technol2022; 38(7): 391–408.
7.
EjioforJUReddyRG.Effects of porous carbon on sintered Al-Si-Mg matrix composites. J Mater Eng Perf1997; 6(6): 785–791.
8.
LiGQuWYLuoM, et al. Semi-solid processing of aluminum and magnesium alloys: status, opportunity, and challenge in China. Trans Nonferr Met Soc China2021; 31(11): 3255–3280.
9.
DangCXieW.Application of aluminum-magnesium alloy material in automobile industry. Hot Work Technol2011; 40(4): 1–4.
10.
XuYChenCJiaJB, et al. Constitutive behavior of a SIMA processed magnesium alloy by employing repetitive upsetting-extrusion (RUE). J Alloys Compd2018; 748: 694–705.
11.
BineshBAghaie-KhafriMShabanM, et al. Microstructural evolution and mechanical properties of thixoformed 7075 aluminum alloy prepared by conventional and new modified SIMA processes. Int J Mater Res2018; 109(12): 1122–1135.
12.
RaghebZDShabestariSGNajafiY.Effect of strain-induced melt activation process and thixoforming on microstructure and mechanical properties of 319 aluminum alloy. J Alloys Compd2023; 954: 170152.
13.
JiangHTYanXQLiuJX, et al. Microstructure and mechanical properties of HIP-ZTC4 during thermal exposure and tensile deformation. Rare Metals2015; 34(10): 692–697.
14.
SuXXuGMJiangDH.Distribution uniformity of added elements in twin-roll cast Al-Zn-Mg-Cu alloy by multi-electromagnetic fields. Rare Metals2015; 34(8): 546–552.
15.
XuHBSunHBYangH, et al. Microstructure and properties of joint for stirring brazing of dissimilar Al/Mg alloy during heating processes. Rare Metals2015; 34(4): 245–250.
16.
JiangJPanXYRenYF, et al. Mechanical properties and micro-structural of Al-Zn-Mg-Cu alloy by semi-solid SIMA processed. Mater Today Commun2023; 37: 107126.
17.
YangLCuiZ.Semi-solid forming technology of aluminum silicon alloy for automobile engine. Forg Stamp Technol2016; 41(2): 73.
18.
HuMLYangLYiW, et al. Entrainment defects in semi-solid A356 aluminum alloy treated by ICTE process. J Alloys Compd2023; 963: 15.
19.
JiangYCLeQCZhuYT, et al. Review on forming process of magnesium alloy characteristic forgings. J Alloys Compd2024; 970: 12.
20.
YongfeiWShengdunZChenyangZ.Numerical simulation of semi-solid die casting technology of bearing cage. Adv Mater Res (Switz)2014; 1044–1045: 75–78.
21.
WangYFZhaoSDGuoY, et al. Deformation characteristics and constitutive equations for the semi-solid isothermal compression of cold radial forged 6063 aluminium alloy. Materials2021; 14(1): 194.
22.
WangYFZhaoSDGuoY.Numerical simulation and experimental investigation of the preparation of aluminium alloy 2A50 semi-solid billet by electromagnetic stirring. Materials2020; 13(23): 5470.
23.
GuopingCTianruiZHongYAN, et al. Comparative research on hot or cold predeformation strain and semi-solid isothermal microstructure of AZ61 magnesium alloy for upsetting in SIMA process. J Plast Eng2008; 15(1): 112–117.
24.
XiaoLZhengWFanX, et al. Preparation technology and microstructure of 100Cr6 steel semi-solid billet by SIMA method with repeated upsetting-stretching. J Plast Eng2020; 27(10): 13–20.
25.
YanHZhangFY. Microstructural evolution of semi-solid AZ61 magnesium alloy during reheating process. In: KangCGKimSKLeeSY (eds) Semi-solid processing of alloys and composites. Solid state phenomena. New York, NY: Wiley, pp.275–278.
26.
ChoudharyCPramanickAKSahooKL, et al. Evaluation of microstructure and mechanical properties of M-SIMA processed Al-7Si alloy. Mater Sci Technol2022; 38(13): 912–925.
27.
ChoudharyCBarHNPramanickAK, et al. Effect of strain induced melt activation process on the microstructure and mechanical properties of Al-5Ti-1B treated Al-7Si alloy. Metals Mater Int2022; 28(10): 2529–2542.
28.
ChoudharyCSharmaSKArifSMD, et al. Development of spherical eutectic Si particles through M-SIMA process and its effects on the tensile properties of Al-7Si-0.05Sr alloy. Silicon2024; 16(7): 2971–2983.
29.
LiMXGuoQWChenLW, et al. Microstructure and properties of graphene nanoplatelets reinforced AZ91D matrix composites prepared by electromagnetic stirring casting. J Mater Res Technol2022; 21: 4138–4150.
30.
ChenLWZhaoYHHouH, et al. Development of AZ91D magnesium alloy-graphene nanoplatelets composites using thixomolding process. J Alloys Compd2019; 778: 359–374.
31.
WangYHLiangXPZengLJ, et al. The microstructure evolution of Al-5Ce alloy prepared by strain-induced melt activation during semi-solid isothermal treatment process. Mater Lett2022; 326: 132948.
32.
JiangJFYanJLiuYZ, et al. Investigation on heat treatment of large-sized and complex AlSi9Mg aluminum alloy components formed by squeeze casting. J Alloys Compd2022; 924: 14.
33.
JiangJFTongZYHuangMJ, et al. Effect of recrystallization annealing on microstructure and properties of cold-deformed CoCrCu1.2FeNi high entropy alloy. J Alloys Compd2024; 973: 13.
34.
LiHCaoMNiuLQ, et al. Establishment of macro-micro constitutive model and deformation mechanism of semi-solid Al6061. J Alloys Compd2021; 854: 18.
35.
ChangMLWangYLiS, et al. Effect of cross-sectional reduction ratio on microstructure evolution of semi-solid 7075 aluminum alloy prepared by RFSIMA process. J Alloys Compd2024; 989: 174355.
36.
PeiHWZhangSGGuoHM, et al. Forming and properties of 7075 aluminum alloy by rheological squeeze casting with transverse mobile injection feed. Int J Adv Manuf Technol2022; 119(11–12): 7969–7981.
37.
FangXRXuHHGaoY, et al. Effect of hammer forging impact characteristics on the forming properties of Ti-6Al-4V alloy. Int J Adv Manuf Technol2022; 123(7–8): 2561–2573.
38.
QiuSZhangCYZhaoL, et al. Finite element simulation and experimental investigation of crystallographic orientation-dependent residual stress in diamond cutting of polycrystalline aluminum. Proc IMechE, Part C: J Mechanical Engineering Science2023; 237(5): 1178–1189.
39.
ShiYJLuSHLiuLT, et al. Research on incremental forming simulation based on an improved constitutive model. Proc IMechE, Part C: J Mechanical Engineering Science2024; 238(15): 7640–7651.
40.
SayadiDMahdikhaniFKhajehzadehM, et al. Corrosion resistance improvement of 6061 aluminum alloy by 2D ultrasonic vibrations assisted turning. Proc IMechE, Part C: J Mechanical Engineering Science2024; 238(4): 895–906.
41.
SandeepRNatarajanA.Application of machine learning approaches to predict joint strength of friction stir welded aluminium alloy 7475 and PPS polymer hybrid joint. Proc IMechE, Part C: J Mechanical Engineering Science2022; 236(16): 9003–9011.
42.
Abd ElnabiMMEl MokademAOsmanT.Optimization of process parameters for friction stir welding of dissimilar aluminum alloys using different Taguchi arrays. Int J Adv Manuf Technol2022; 121(5–6): 3935–3964.
43.
WangYFZhaoSDZhaoXZ, et al. Effects of isothermal treatment parameters on the microstructure of semisolid alloys. Mater Sci Technol2018; 34(1): 104–110.
44.
WangYFXiongLHFengDX, et al. Investigation of the penetration performance of the radial forging process for wrought aluminium alloy. Materials2024; 17(9): 17.
45.
GautamSKSinghBK.Investigation on the effects of isothermal holding temperature and time on the coarsening mechanism and rheological properties of ADC12 Al semi-solid slurry. Mater Chem Phys2024; 314: 11.
46.
ShabestariSGAbdiMNaghdaliS.Effect of thixoforming and precipitation hardening on microstructure and mechanical properties of Al-10.5Si–3Cu-0.2Mg alloy produced by strain induced melt activation process. J Mater Res Technol2021; 15: 4981–4992.
47.
JiangHAnLLiF, et al. Numerical and experimental study on the rheo-extrusion process of 2A50 aluminium alloy miniature gear. J Mater Res Technol2023; 24: 1468–1482.
48.
ZhangQQCaoZYZhangYF, et al. Effect of compression ratio on the microstructure evolution of semisolid AZ91D alloy. J Mater Process Tech2007; 184(1–3): 195–200.
49.
MoshtaghiMSafyariMKuramotoS, et al. Unraveling the effect of dislocations and deformation-induced boundaries on environmental hydrogen embrittlement behavior of a cold-rolled Al–Zn–Mg–Cu alloy. Int J Hydrogen Energy2021; 46(11): 8285–8299.
