Numerical Simulation and Experimental Verification of Nickel-Based Superalloy Disc-Shaped Parts Formed by Semi-Solid Thixoforming

Abstract

Numerical simulation of the thixoforming process of GH4037 nickel-based superalloy disc-shaped components is performed using DEFORM-3D software (Deform V11). The complete numerical simulation process includes three stages in this work: heat transfer to air, heat transfer on the ejector rod, and the semi-solid thixoforming process. The effects of billet placement, billet temperature, and extrusion velocity on the numerical simulation of thixoforming were investigated. Furthermore, some disc-shaped components were produced through thixoforming to verify the results of numerical simulation. The simulation results indicate that horizontal billet placement is beneficial to the thixoforming of the GH4037 part. A higher billet temperature is good for the filling of disc-shaped components, and the formed part is completely filled when the billet temperature is higher than 1360 °C. Higher extrusion velocity leads to lower effective stress of the disc-shaped component. However, high extrusion velocity easily leads to the separation of solid and liquid phases and aggravates the wear and impact of the dies. The experimental results of thixoforming are in good agreement with the results of numerical simulation, and GH4037 nickel-based superalloy disc-shaped components with complete filling and good surface quality are obtained under the optimized process parameters.