Semi-solid die forging of Al6061 wrought aluminium alloy with electromagnetic stirring

Abstract

This study demonstrates the forming process of a semi-solid material with a solid fraction of about 45 per cent after the primary α-Al particle in the semi-solid material is globularized during solidification by electromagnetically stirring the molten metal poured out into the sleeve. By rheological forming experiments incorporating electromagnetic stirring (EMS) using Al6061 alloy, the process parameters are optimized to be of 0.3 m/s of forming velocity, 45 MPa of forming pressure, 10 s of stirring time, and 30 A of stirring current to get the best quality. The product exhibited the highest tensile strength of 312.8 MPa and elongation of 4.51 per cent at positions where the pressure was directly applied to the material and overlapping occurred.