DEVELOPMENT OF TWIN-SCREW RHEO-EXTRUSION PROCESS

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1 DEVELOPMENT OF TWIN-SCREW RHEO-EXTRUSION PROCESS K. A. Roberts and Z Fan Department of Mechanical Engineering, Brunel University, Uxbridge, Middlesex, UB8 3PH, UK Summary Conventional hot extrusion reductions are achieved through large plastic deformations requiring a number of processing steps and large loads, this is time consuming and expensive. Due to processing conditions the final microstructures are often non-uniform and prone to defects. To overcome such shortcomings, a twin-screw rheo-extrusion (TSRE) process has been recently developed at Brunel University. The TSRE equipment consists of four basic units, a liquid metal feeding system, a twin-screw extruder, a gear pump and an extrusion die. During the continuous process, liquid metal is fed into the twin-screw extruder, where it is cooled and sheared simultaneously to produce the desirable semi-solid metal (SSM) slurry. The SSM slurry is then passed to a gear pump to the extrusion die for the final solidification and profile creation. TSRE is a one step process decreasing both processing time and labour time; as a result productivity is increased. Processing semisolid metal reduces the necessary extrusion pressures, preserving die life and equipment, whilst reducing energy consumption. Finally the TSRE process produces fine, spherical solid particles in a uniform microstructure consistent throughout the bar. This paper presents the TSRE process and equipment. The experimental results on rheo-extrusion of Sn-15Pb alloys will also be discussed. Keywords: Semisolid; Processing; Rheoextrusion. 1. Introduction 1.1 Conventional Hot Extrusion of metals and the consequential microstructure Conventional extrusion is a deformation process to produce a reduction in diameter and form desired shapes from cylindrical billets. This is accomplished by forcing the billet through a die at high pressure, therefore requiring large forces. Higher extrusion temperatures reduce the required flow stress but introduce problems of oxidation, softening of tooling and hot shortness. Extrusion forces must overcome friction and be adequate to provide the necessary extrusion ratio. Lubrication of billets reduces friction and does improve microstructure, but non-uniform deformation still occurs. This results in grain size and morphology variations throughout the extruded section producing anisotropic properties. The anisotropy is magnified by the presence of extrusion defects such as oxide inclusions. Surface cracking occurs if extrusion too fast but the high compressive stresses created within the billet reduces the risks of cracking in service.

2 1.2 Development in semisolid metal processing Since the early studies at the MIT of rheocasting as a single stage process [1], most consequential research into the semisolid field has been based on the two-step route, or thixo route. The initial research into semisolid slurries from the rheo route was restricted due its very nature of starting with liquid metal. The dominating steel industry seemed an unlikely host of the research due to high working temperatures, and lower temperature metals such as Aluminium have the obstacle of volatility. This, combined with the dislike of mixing a foundry with the workshop led to the enhanced development of the thixo route over the rheo route. By cutting up a previously cast billet of specific microstructure, and reheating to the SS range for shaping, the problems associated with liquid metal temperature are eliminated. Much money and time has been spent over the last 30 years on this area of SSM, but although the superior microstructure is accomplished, the cost implications of the feedstock required for thixoforming operations have restricted its industrial advance. 1.3 Semisolid Processes As an alternative to conventional hot extrusion, semisolid processing methods have been investigated, the main contender being Thixoextrusion as developed at the University of Technology- Aachen. A container is heated to the semisolid range before a billet is introduced and extruded, superior microstructure is achieved and reduced extrusion forces are required to attain them [2,3]. However in an industrial climate, finance is a significant consideration to application, and therefore necessity of semisolid feedstock is a huge drawback introducing the possibility of development in rheoextrusion. It is the objective of this study to do just that with a new process recently developed at Brunel University, Twin-Screw Rheo-extrusion (TSRE). The process is centred on the previously recognised technology developed at Brunel University, of Twin-Screw Rheomoulding [4]. A tin-lead alloy of composition 85-wt % tin 15-wt % lead is used to develop this process and the findings used to convey the application of the process to the die casting magnesium alloy AZ91D for further trials of confirmation as a viable alternative to conventional hot extrusion. Discussions will be focused on the inherent advantages incurred through TSRE over conventional hot extrusion and the development results of rheo-extrusion. 2. The Twin-Screw Rheo-extrusion Process The developed twin-screw rheo-extrusion process is represented in Figure 1.The TSRE equipment consists of four basic units, a liquid metal feeding system, a twin-screw extruder, a gear pump and an extrusion die. The liquid metal feeder supplies liquid metal of the desired temperature to the twin-screw extruder, which acts as a slurry maker. The gear pump is used to regulate the extrusion pressure and speed. During the rheoextrusion process, liquid metal is fed into the twin-screw extruder with a controlled feed rate through a liquid metal pump. The co-rotating, intermeshing screws create a desirable semisolid metal (SSM) slurry by shearing and cooling the metal simultaneously. The SSM slurry is then passed to a gear pump to regulate the extrusion pressure and speed. The extrusion die acts as a device for the final

3 solidification and for creating the final profile. All these procedures are performed in a continuous manner and controlled by a central control unit Figure1: Schematic if Twin-Screw Rheo-Extrusion Process. 1. Motor, 2. Gearbox; 3. Liquid metal feeder, 4. Twin-screws, 5. Heating and cooling elements, 6. Gear pump, 7. Extrusion die, 8. Thermocouples, 9. Barrel housing. 3. Experiment 3.1 Material preparation Industrially pure Sn and Pb were weighed and melted in a furnace to create Sn-15%wt. Pb alloy. The molten alloy was kept in a graphite crucible, and was stirred to maintain chemical homogeneity. A similar process was used with Mg alloy AZ91D, though a protective Argon gas was used during melting in the furnace. 3.2 Microstructural observation The samples were prepared so that microstructures could be observed. The extruded specimens were reduced to smaller, more manageable sizes and the microstructures revealed; the samples were mounted in a cold hardening polyester resin. A machine disc grinder was used with Silicon Carbide abrasive paper of grades 180, 400, 800 and 1200-micron grits, successively. In between papers the samples were washed thoroughly. The samples were initially polished on a clean polishing cloth with a six-micron alumina paste. The final polish was completed with a one-micron paste. The samples were etched in: Glycerol 80 per cent, Acetic acid 10 per cent, and Nitric acid 10 per cent, to produce sufficient contrast for the examination of microstructure. The microstructures were observed using optical microscopy and digital images of these observations were captured, allowing point intercept to be performed to calculate volume fractions, at least 500 points were used for every selected sample.

4 4. Results of trials The Sn-15wt%Pb alloy was poured at 220 C and was sheared at 184 C for 30secs at 800rpm (3265s -1 ) before extrusion. The microstructure observed through the section of the rheoextruded bar is shown in figure 2. Optical micrographs were taken of both the bulk and edge microstructure, to show the consistent profile throughout the cross-section of the bar. The effects of processing conditions on the quality of the final extrudate were tested, the conditions were altered to change the semisolid slurry created before final extrusion. This was to indicate preferential parameters to create a desirable SSM slurry for a successful process outcome. The observations are summarised in Table 1. a) b) Figure 2: Optical micrographs showing the microstructures at a) the edge and b) the center of a Rheoextruded Sn-15wt%Pb bar. Shearing Shear time (s) Shear rate (s -1 ) Solid fraction Quality of extrudate Temperature ( C) (30rpm) Although profile good cracking in shell (200rpm) Good profile, good surface (200rpm) Good surface but no profile maintenance Table 1: Effects of processing conditions. Sheet extrusion was simulated with the Sn-15wt.%Pb alloy, the cross-sectional microstructure of the sheet may be observed in Figure 3. The large solid particles are from primary solidification; the finer solid particles are from the secondary solidification of the remnant liquid. This image shows that the microstructure produced by the Twin-screw rheoextrusion process is stable from edge to edge of the sample regardless of die profile. On completion of the preliminary trials with the Sn-15%wt. Pb alloy, a trial was completed using the AZ91D alloy. The alloy was poured at 220 C and was sheared at 184 C for 30secs at 800rpm (3265s -1 ) before extrusion. The microstructure observed through the section of the rheoextruded bar is shown in figure 4.

5 Figure 3: Optical micrograph of the Rheoextruded Sn-15wt%Pb sheet. a) b) Figure 4: Optical micrographs showing the microstructures at a) the center and b) the edge of a Rheoextruded AZ91D bar. 5. Discussion 5.1 Advantages of TSRE Conventional Hot extrusion is limited in its ability to produce very small diameter reductions due to the large forces necessary to accomplish them. The frictional forces associated with conventional extrusion techniques not only increase the required extrusion forces, but also increases wear of equipment and dies. This is the huge benefit of using SSM; the TSRE process inherently can achieve very small diameters as a consequence of requiring less force in extrusion, the frictional forces being less than solid metal. Additionally the lower flow stresses experienced in forming SSM imply that TSRE will be suitable for more complex extrusion profiles. The net shaping capabilities of TSRE and indeed most semisolid processing allows products to be used directly, not always the case for traditional metal processing techniques.

6 Conventionally, most research in the area of SSM processing has followed the Thixo route; the research at Brunel has focused on the Rheo route. Thixo processes are reliant on their feedstock to provide good rheological properties to allow easy handling and loading. With rheo processing techniques the elimination of special feedstock: reduces costs, process complexity, and transportation requirements. The entire one step process can be kept in house and materials are 100% recyclable. The microstructure is characteristic of all semisolid processing methods, with uniform spherical primary particles and fine spherical secondary particles. 5.2 TSRE Parameters. The creation of a desirable SSM slurry for the TSRE process is crucial to the quality of production and maintenance of the microstructure. The temperature control is by far the most significant parameter in the TSRE process. Coupling this with maximum turbulence created by the twin-screw configuration while controlling shear rate and time, a sound SSM slurry is produced. Volume fraction of the semisolid slurry was significant to the success of the rheoextrusion process and found to be the quantifiable parameter to a desirable slurry. If too much liquid were present in the slurry then on rheoextrusion it would not maintain its form. However if solid fraction was too high, then on rheoextrusion, surface cracking occurred. Table 1 therefore gives a guideline to the necessary processing conditions to produce the desirable semisolid slurry for the TSRE process. 6. Conclusions This process has proved to be a viable alternative to conventional hot extrusion processes both economically and practically. The significance of a desirable SSM slurry was seen in the trials. Continuation of trials to understand rheology and mechanical properties created by the TSRE process is the natural step from this early development work. The potential reduction in both process cost and complexity to that of traditional techniques is an incentive to industrial application. The ability of TSRE to produce high tolerance, complex profiles and net shaped products leaves the process well suited to many industrial tasks. References [1] Flemings, M.C., Riek, R.G. and Young, K.P.: Rheocasting, Materials Science and Engineering, Vol. 25 (1976), [2] Kopp, R., Mertens, H.-P., Wimmer, M., Winning, G. and Witulski, N.: Thixoextrusion of Aluminium Wrought alloys, 5 th Int l Conf. on SSP of alloys and composites (1998) USA. [3] Kopp, R., Moller, T., Neudenberger, D. and Winning, G.: Thixoforging and Thixoextrusion- benefits of innovative forming technologies, 6 th ITCP, (1999). [4] Ji, S., Fan, Z. and Bevis, M.J.: Semi-solid Processing of engineering alloys by a twinscrew rheomoulding process, Materials Science and Engineering A, Vol.299 (2001),

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