Abstract
A steel thixocasting experiment was carried out using self‐heating alumina moulds operating at ∼1000°C. An industrially manufactured diving knife was selected as workpiece geometry to examine the ability of near‐net shaping complex steel structures by semisolid processing. Results show that a significant reduction in machining effort can be achieved, and engineered surfaces of a characteristic size of at least less than 30 μm can be generated in situ without additional surface treatment. It is concluded that the intended decrease in forming forces and the increase in shape complexity in comparison to forging can be accomplished using highly preheated ceramic moulds. Considerable construction work on tool implementation has to be carried out to improve performance of the alumina moulds with respect to the applied process forces.
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