Numerical Simulation on the Die Filling Process of the Thixo-Forging of Al-7 wt pct Si/Al-22 wt pct Si Bimetal Composite

A bimetal semi-solid fluid has more complicated flow behaviors than a normal semi-solid fluid during thixo-forging. In order to clarify the detailed properties of the bimetal thixo-forging, the effects of billet temperatures and frictions on flow behaviors of the Al-7 wt pct Si/Al-22 wt pct Si bimetal thixo-forging were investigated by commercial software DEFORM-3D. The simulation results show that shear force was unable to be transferred from the upper billet on the drop die side to the bottom billet on the counter die side efficiently in the initial stage of die filling. Only when the upper billet severely deformed, did the shear force deform the bottom billet. A stiffer upper billet can enhance the efficiency of shear force transfer. The processing temperature, the relative stiffness between the upper billet and bottom billet, and frictions between dies and billets, as well as friction between billets, were important factors to control the interface outline of the bimetal parts. The experimental results are consistent with the simulation results.