Lightweight near net shape components produced by thixoforming

Recent thixoforming development work at EFU has been concentrated on: (1) improved machine concepts for serial production, (2) die design and prototype manufacturing from various light metals including magnesium and metal matrix composites, (3) numerical simulation for process optimization, (4) accessing process benefits through the appropriate use of design options (specially designed steering knuckle demonstrator). A pilot thixoforming system consisting of four EFU heating modules with patented sensor systems, an ABB robot for billet handling and a Frech 5,8 MN real time controlled high pressure die casting machine has been used to produce various prototype parts. The process parameters have been examined with incomplete die filling experiments and numerical simulation. To exploit the full potential of the thixoforming process, a steering knuckle for a compact passenger car has been redesigned, thixoformed and tested. The weight of the new part is approx. 35% below that of a conventional forged steel design, despite identical functional capabilities. © 1997 Elsevier Science Ltd.