Ultrasonic sensor development for the semi-solid metal working process

Bernhard R. Tittmann, M. Huang, C. Moose, A. Niessner

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

Semisolid Metalworking (SSM) is a hybrid manufacturing process that incorporates the advantages of both casting and forging. However, high volume commercial production has suffered from inadequacies in process monitoring and control. A key process parameter is the SSM solid-liquid fraction, which is a sensitive indicator of the deformation and flow behavior of the material during forming. Unfortunately, no sensor currently exists to provide an in-situ measurement of this important parameter. Here we present preliminary results for an advanced ultrasonic sensor to measure solid fraction. With the aid of metal alloy phase diagrams the binary alloy Sn-Bi was chosen to simulate behavior of Al/Si (e.g., 300 series) alloys. The phase diagram was used to provide the value of solid fraction at any given temperature. Measurements with longitudinal ultrasonic waves at 1 MHz in the selected alloy heated to different solid fractions were performed with a combination of commercial transducers and quartz buffers penetrating into a temperature controlled furnace. Five compositions were used ranging from 83% to 100% -Bi in the binary Sn-Bi alloy. Presented are measurements of longitudinal wave velocity as a function of temperature across the entire range from totally solid to semi-solid to liquid states in both heating and cooling runs. The curves show the characteristic phase transitions. A quasi-static viscoelastic model based on Atkinson, Kytömaa and Berryman was prepared and modified for the SSM application. The comparison of the model calculations with the experimental results were in reasonable agreement. With the recent development of high temperature ultrasonics our results provide a potential solution to the development of an ultrasonic sensor for SSM.

Original languageEnglish (US)
Title of host publication2005 IEEE Ultrasonics Symposium
Pages1266-1269
Number of pages4
Volume2
DOIs
StatePublished - Dec 1 2005
Event2005 IEEE Ultrasonics Symposium - Rotterdam, Netherlands
Duration: Sep 18 2005Sep 21 2005

Other

Other2005 IEEE Ultrasonics Symposium
CountryNetherlands
CityRotterdam
Period9/18/059/21/05

Fingerprint

metal working
semisolids
ultrasonics
sensors
phase diagrams
forging
longitudinal waves
ultrasonic radiation
binary alloys
liquids
in situ measurement
furnaces
temperature
transducers
manufacturing
quartz
buffers
cooling
heating
curves

All Science Journal Classification (ASJC) codes

  • Acoustics and Ultrasonics

Cite this

Tittmann, B. R., Huang, M., Moose, C., & Niessner, A. (2005). Ultrasonic sensor development for the semi-solid metal working process. In 2005 IEEE Ultrasonics Symposium (Vol. 2, pp. 1266-1269). [1603082] https://doi.org/10.1109/ULTSYM.2005.1603082
Tittmann, Bernhard R. ; Huang, M. ; Moose, C. ; Niessner, A. / Ultrasonic sensor development for the semi-solid metal working process. 2005 IEEE Ultrasonics Symposium. Vol. 2 2005. pp. 1266-1269
@inproceedings{9889083d32274ce9b9fac68b64535889,
title = "Ultrasonic sensor development for the semi-solid metal working process",
abstract = "Semisolid Metalworking (SSM) is a hybrid manufacturing process that incorporates the advantages of both casting and forging. However, high volume commercial production has suffered from inadequacies in process monitoring and control. A key process parameter is the SSM solid-liquid fraction, which is a sensitive indicator of the deformation and flow behavior of the material during forming. Unfortunately, no sensor currently exists to provide an in-situ measurement of this important parameter. Here we present preliminary results for an advanced ultrasonic sensor to measure solid fraction. With the aid of metal alloy phase diagrams the binary alloy Sn-Bi was chosen to simulate behavior of Al/Si (e.g., 300 series) alloys. The phase diagram was used to provide the value of solid fraction at any given temperature. Measurements with longitudinal ultrasonic waves at 1 MHz in the selected alloy heated to different solid fractions were performed with a combination of commercial transducers and quartz buffers penetrating into a temperature controlled furnace. Five compositions were used ranging from 83{\%} to 100{\%} -Bi in the binary Sn-Bi alloy. Presented are measurements of longitudinal wave velocity as a function of temperature across the entire range from totally solid to semi-solid to liquid states in both heating and cooling runs. The curves show the characteristic phase transitions. A quasi-static viscoelastic model based on Atkinson, Kyt{\"o}maa and Berryman was prepared and modified for the SSM application. The comparison of the model calculations with the experimental results were in reasonable agreement. With the recent development of high temperature ultrasonics our results provide a potential solution to the development of an ultrasonic sensor for SSM.",
author = "Tittmann, {Bernhard R.} and M. Huang and C. Moose and A. Niessner",
year = "2005",
month = "12",
day = "1",
doi = "10.1109/ULTSYM.2005.1603082",
language = "English (US)",
isbn = "0780393821",
volume = "2",
pages = "1266--1269",
booktitle = "2005 IEEE Ultrasonics Symposium",

}

Tittmann, BR, Huang, M, Moose, C & Niessner, A 2005, Ultrasonic sensor development for the semi-solid metal working process. in 2005 IEEE Ultrasonics Symposium. vol. 2, 1603082, pp. 1266-1269, 2005 IEEE Ultrasonics Symposium, Rotterdam, Netherlands, 9/18/05. https://doi.org/10.1109/ULTSYM.2005.1603082

Ultrasonic sensor development for the semi-solid metal working process. / Tittmann, Bernhard R.; Huang, M.; Moose, C.; Niessner, A.

2005 IEEE Ultrasonics Symposium. Vol. 2 2005. p. 1266-1269 1603082.

Research output: Chapter in Book/Report/Conference proceedingConference contribution

TY - GEN

T1 - Ultrasonic sensor development for the semi-solid metal working process

AU - Tittmann, Bernhard R.

AU - Huang, M.

AU - Moose, C.

AU - Niessner, A.

PY - 2005/12/1

Y1 - 2005/12/1

N2 - Semisolid Metalworking (SSM) is a hybrid manufacturing process that incorporates the advantages of both casting and forging. However, high volume commercial production has suffered from inadequacies in process monitoring and control. A key process parameter is the SSM solid-liquid fraction, which is a sensitive indicator of the deformation and flow behavior of the material during forming. Unfortunately, no sensor currently exists to provide an in-situ measurement of this important parameter. Here we present preliminary results for an advanced ultrasonic sensor to measure solid fraction. With the aid of metal alloy phase diagrams the binary alloy Sn-Bi was chosen to simulate behavior of Al/Si (e.g., 300 series) alloys. The phase diagram was used to provide the value of solid fraction at any given temperature. Measurements with longitudinal ultrasonic waves at 1 MHz in the selected alloy heated to different solid fractions were performed with a combination of commercial transducers and quartz buffers penetrating into a temperature controlled furnace. Five compositions were used ranging from 83% to 100% -Bi in the binary Sn-Bi alloy. Presented are measurements of longitudinal wave velocity as a function of temperature across the entire range from totally solid to semi-solid to liquid states in both heating and cooling runs. The curves show the characteristic phase transitions. A quasi-static viscoelastic model based on Atkinson, Kytömaa and Berryman was prepared and modified for the SSM application. The comparison of the model calculations with the experimental results were in reasonable agreement. With the recent development of high temperature ultrasonics our results provide a potential solution to the development of an ultrasonic sensor for SSM.

AB - Semisolid Metalworking (SSM) is a hybrid manufacturing process that incorporates the advantages of both casting and forging. However, high volume commercial production has suffered from inadequacies in process monitoring and control. A key process parameter is the SSM solid-liquid fraction, which is a sensitive indicator of the deformation and flow behavior of the material during forming. Unfortunately, no sensor currently exists to provide an in-situ measurement of this important parameter. Here we present preliminary results for an advanced ultrasonic sensor to measure solid fraction. With the aid of metal alloy phase diagrams the binary alloy Sn-Bi was chosen to simulate behavior of Al/Si (e.g., 300 series) alloys. The phase diagram was used to provide the value of solid fraction at any given temperature. Measurements with longitudinal ultrasonic waves at 1 MHz in the selected alloy heated to different solid fractions were performed with a combination of commercial transducers and quartz buffers penetrating into a temperature controlled furnace. Five compositions were used ranging from 83% to 100% -Bi in the binary Sn-Bi alloy. Presented are measurements of longitudinal wave velocity as a function of temperature across the entire range from totally solid to semi-solid to liquid states in both heating and cooling runs. The curves show the characteristic phase transitions. A quasi-static viscoelastic model based on Atkinson, Kytömaa and Berryman was prepared and modified for the SSM application. The comparison of the model calculations with the experimental results were in reasonable agreement. With the recent development of high temperature ultrasonics our results provide a potential solution to the development of an ultrasonic sensor for SSM.

UR - http://www.scopus.com/inward/record.url?scp=33847092439&partnerID=8YFLogxK

UR - http://www.scopus.com/inward/citedby.url?scp=33847092439&partnerID=8YFLogxK

U2 - 10.1109/ULTSYM.2005.1603082

DO - 10.1109/ULTSYM.2005.1603082

M3 - Conference contribution

SN - 0780393821

SN - 9780780393820

VL - 2

SP - 1266

EP - 1269

BT - 2005 IEEE Ultrasonics Symposium

ER -

Tittmann BR, Huang M, Moose C, Niessner A. Ultrasonic sensor development for the semi-solid metal working process. In 2005 IEEE Ultrasonics Symposium. Vol. 2. 2005. p. 1266-1269. 1603082 https://doi.org/10.1109/ULTSYM.2005.1603082