Thixoforming of Steels - A Status Report

The Thixoforming of metals is a new forming technology, which combines the advantages of casting and forging. This technology focuses on structural components with complex shapes, which can not be manufactured using conventional processing methods. Different components made of aluminum and magnesium are already industrially produced. Apart from this, the use of steels in the Thixoforming processes is still being researched and developed. During the last years it became obvious that the Thixoforming of steels may not be a complete substitution for highly automated die-casting or forging processes, but rather a new process route to produce special components with high quality and geometrical demands. Special interest lies in the development and production of filigree components, parts with voids or undercuts, integrated elements such as tubes or tube-systems and joining pieces or products made of different materials. Beside the design of suitable tool materials and tool concepts, the development of homogeneous heating strategies and the development of thixoformable steels is at the center of current research. Therefore, this paper focuses on material requirements which are needed for the Thixoforming of steels and on the production of components and occurring problems. By use of a failure catalogue for Thixoforming of steels, reasons for characteristic failures and suggestions are given to avoid them, so that the quality of thixoformed parts can be improved.