DEFECT CONTROL IN THIXOMOLDING PROCESS AZ91D PRESENTED BY PRASHANT PATEL

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1 MICROSTRUCTURE EVALUATION DEFECT CONTROL IN THIXOMOLDING PROCESS AZ91D PRESENTED BY PRASHANT PATEL

2 OUT LINE FOR PRESENTATION INTRODUCTION THIXO-MOLDING PROCESS DEFECTS IN CASTING EXPERIMENTAL DETAILS RESULT AND ANALYSIS CONCLUSION REFERENCES 2

3 INTRODUCTION In 1971 D.Spencer found thixotoropy phenomenon in semisolid metal. In 1970 M.Flemings developed metal molding technology with applying thixotoropy concept. In 1990 s JSW Co. Ltd developed injection molding machine for Mg Alloy. Thixotoropy Apparent viscosity changes reversibly by stirring. High stir speed High apparent viscosity Low stir speed Low apparent viscosity 3

4 THIXO-MOLDING PROCESS Thixo-molding is a relatively new and environmental fi friendly technique for production of highh quality magnesium parts that is near net-shape. Due to a low casting temperature near the liquidus or even in the semi-solid regime Fewer blow holes Less shrinkage Fewer hot cracks Smaller distortion Higher dimensional accuracy 4

5 Fig: 1 Schematic drawing of Thixo-molding machine (M.Scharrer 2006) Material Composition (Czerwinski et.al. 2001) CHIP Al Zn Mn Si Fe Cu Ni Mg < 0.01 < Balance MA ATERIAL 5

6 DEFECTS IN CASTING SINKS POOR FILL LAMINATION SHRINKAGE PORISITY CRACKS Fig: 2 Picture From: NADCA.ORG 6

7 EXPERIMENTAL DETAILS PART CREATE SAMPLE ANALYSIS OF SAMPLE Fig: 3 (Cana-Datum Moulds Ltd) 7

8 EXPERIMENTAL DETAILS NAME Density Melting Thermal Tensile Yield Young s Elongati Specific temperat conducti strengt strengt modulu on strengt ure vity h h s h Magnesium alloy (Thixomolding) (g/cm 3 ) ( C) (W/Mk) (MPa) (MPa) (%) (GPa) AZ AM Aluminum alloy (die casting) Steel carbon steel Plastics ABS (Tg) * PC (Tg) * Table 1: Physical Properties of Different Metals (Wang,et.al. 2010) 8

9 EXPERIMENTAL DETAILS Different Barrel Temperature Different Screw Rotation Speed Different Injection Velocity Different Mold Temperature 9

10 RESULTS AND ANALYSIS Different Barrel Temperature (a) 580 º c (b) 590 º c (c) 600 º c (d) 610 º c Injection Speed 2.09 m/s Screw Rotation 168 rpm Mold Temperature 280 º c Fig: 4 Microstructure of AZ91D at various barrel temperature (Y.F.Zhang,et.al.2007) 10

11 RESULTS AND ANALYSIS Different Screw Rotation Speed (a) 105 rpm (b) 143 rpm (c) 168 rpm Injection Speed 2.09 m/s Barrel Temperature 600 º c Mold Temperature 230 º c Fig: 5 Microstructure of AZ91D at various screw rotation speed (Y.F.Zhang,et.al.2007) 11

12 RESULTS AND ANALYSIS Microstructure Evolution Mechanism Fig: 6 Schematic illustration of morphological transition from dendritic to spherical via rosette: (a) deformed dendritic (b) recrystallization and solute diffusion (c) solute segregation, detaches and disintegration (d) coalescence and (e) Ostwald ripening and spheroidization. (Y. F. Zhang, et al. 2007) 12

13 CONCLUSION The mechanism of nucleation and growth of the solid particle was effective for generation and evolution of non- dendritic microstructure including the particle with entrapped liquid. The size of the solid particles reduces with the increasing barrel temperature while the morphology was not essentially affected. The screw rotation speed was controlling the size reduction and the increase of the sphericity of the solid particles. The breakdown and growth of the particle were accelerated with increasing the screw rotation speed. Due to high cooling rate caused by the low injection velocity or low mold temperature refinement of the solid particles occurred. The critical solid fraction about 10-20%, the particle grating considered as the change point of coalescence and Ostwald ripening. (Y. F. Zhang, et al. 2007) 13

14 REFERENCES Czerwinski, F. Scripta Mater. 48, 2003: Czerwinski, F. Acta Mater. 50, 2002: Czerwinski, F. "Magnesium Injection Molding [M]. New York. " Springer Verlag, 2008: Czerwinski, F, A Zielinska-Lipiec, P J Pinet, and J Overbeeke. "Correlating the Microstructure and Tensile Properties of a Thixomolding AZ91D Magnesium Alloy." Acta mater. 49, 2001: feb 12, Mullins, W W, and R F Sekerkar. "Morphological stability of a particle growing by diffusion or heat flow [J]." J Appl Phys., 1963, 34: NADCA.ORG. Die casting defects - causes and solutions. Seminar training, NADCA.org, n.d. Zhang, Y F, Y B Liu, Q Q Zhang, Z Y Cao, X P Cui, and Y Wang. "Microstructural evolution of thixomolding AZ91D magnesium alloy with process parameters variation." Materials Science and Engineering A 444, 2007: Zhang, You fa, Yong bing Liu, and Zhan yi Cao. "Microstructure characteristics and solidification behavior of thixomolded Mg-9%Al-1%Zn alloy." Trans. Nonferrous Met. Soc. China, 2011: Zhang, You fa, Yong bing Liu, and Zhan yi Cao. "Microstructure transformation of deformed AZ91D during isothermal holding [J]." Transaction of Nonferrous Metals Society of China, 2010, 20(1)::

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