The application of semisolid process was investigated on Pb-Sb alloys that are normally used for metallic parts in car batteries, in order to increase their mechanical properties and corrosion resistance. The semisolid behaviour of a Pb-4%Sb alloy was analysed by means of rheological and calorimetry differential scanning experiments. The alloy was melted, treated by ultrasound to obtain the semisolid state and then poured into permanent moulds. Some of these samples were also heated in semisolid temperature range and injected in thixo-casting apparatus. Both poured and injected samples were characterized by metallographic analysis, mechanical test and electrochemical corrosion experiments. The results show an improvement of mechanical and corrosion resistance with respect to samples obtained by conventional casting technique.

Since the automotive industry has many possible applications for semi-solid metal (SSM)−high-pressure die casting (HPDC) parts, the newly developed heat treatment cycles, as well as the traditional heat treatment cycles, were applied to A356 brake calipers cast using a LK DCC630 HPDC machine. Vickers hardness measurements at a cross section of the brake calipers were performed, indicating that similar values can be obtained when using the significantly shorter heat treatment cycles. Finally, the typical tensile properties that can be obtained for SSM-HPDC A356 brake calipers are compared with those manufactured by gravity die casting. Results indicate that the differences in microstructures (globular or dendritic) do not have a noteworthy effect on the heat treatment response. This implies that the short heat treatment cycles originally developed for globular SSM-HPDC A356 castings can be successfully applied to dendritic liquid A356 castings too.

The thixocasting process was chosen to produce the impellers as it is capable of producing castings with extremely high internal quality. Slugs cut from the DC cast bars are re-heated to the semi-solid casting temperature, and a specially-designed runner and gating system is used to prevent oxide from the surface of the slugs from becoming incorporated into the impeller. The technology used to produce the semi-solid impellers is described in detail. The semi-solid cast impellers, produced from an Al-Si-Mg-Cu alloy, are heat treated to the T6 temper. Results from testing are presented demonstrating that the impellers are free of porosity and other internal defects. Both mechanical property and fatigue data are presented showing that the semi-solid impellers have better properties than impellers produced by conventional casting and similar properties to forged and machined impellers. A short study is also described which identified suitable processing parameters to minimize hot tearing in the complex-shaped turbocharger impellers semi-solid cast from alloy 201. The surfaces of the impellers were examined using penetrant testing, and the results of modifying processing parameters on the propensity for surface cracking are presented. An aging study was performed to identify optimum mechanical strength.

A method to reach the globular weld structure of A356 aluminum alloy using stirring the localized semisolid zone during butt-joining is developed. Since the heat conductivity of this alloy is very high, the accurate controlling of temperature during joining must be considered. A gas heating system was used to heat up the nitrogen gas up to the required temperature. A dried and free oxygen gas was prepared when a stream of nitrogen gas could pass closely around a hot element. Hot and pure nitrogen gas flow through a precise ceramic nozzle was used to create a localized semisolid pool. At this stage a fine stirrer was introduced into the weld seam in order to mix the two sides into a single uniform joint. Substrates were moved in direction of joint line by a small trolley to avoid the deviation of nozzle from the joint line and its distance and angle from the substrate. A fixture system was used to hold two substrates together on the trolley. A narrow hot plate was located on the trolley to heat up the joint line due to high heat conductivity of aluminum. Effect of gas temperature was investigated on the microstructure and mechanical properties of weld seam. Results showed that increase in temperature promoted the final welding properties, and also at liquid fractions less than 50% joining was not fully practical. The best mechanical properties were achieved with liquid fraction of about 70%.

Sand casting and die casting processes have been used widely for complex automotive products such as knuckle, arm, etc. Usually, a part fabricated by casting has limited strength due to manufacturing defects such as the dendrite structure, segregation and porosities. As an attempt to offer a solution to these problems, forging has been used as an alternative process. However, the forging process provides limited formability for complex shape products. Rheo-forging of metal offers not only superior mechanical strength but also requires significantly lower machine loads than solid forming processes. In order to produce semi-solid materials of the desired microstructure, a stirring process is applied during solidification of molten metal. The results of an A356 aluminum alloy sample, which are obtained by experiment and by simulation using DEFORM 3D, are present.

In order to adapt to the trend of “energy saving and emission reduction” and impel the practical application of semi solid processing (SSP) in China, the progress and application of semi-solid theory in China have been reviewed briefly and systematically. It was emphasized on basic theories, such as formation of globular grains, rheology, high pressure solidification and plastic deformation and applications, such as material design, preparation of semi-solid billets (slurries), thixoforming and application status, which are based on the advantage of semi-solid processing. The results show that the gap of SSP between world level and China exists, especially in application technologies, including market recognition, application fields exploiting, developing of billets (slurries) preparation technologies with low cost and special equipments. The prospect of semi-solid forming development path in China is presented. And we hope that application of SSP has great new breakthrough and development and China will be changed from a large metal processing country to a powerful metal processing country.