Application of the finite element method to predict material flow and defects in the semi-solid forging of A356 aluminum alloys

Research in the production of the semi-solid materials, process modeling and development of the constitutive flow behavior is required to assist the industrial application of Semi-Solid Forging (SSF) technology. This paper presents the results of the finite element simulations of semi-solid forging of A356 disks using DEFORM code. Although approximated flow stress curves of semi-solid A356 aluminum alloy were used, deformation characteristics were found to be in good agreement with the experiments performed at EFU, Germany. Particularly, folding defects and their "rewelding" were predicted with enough accuracy. Use of actual flow stress curves, when available, would provide more accurate predictions of the loads required to forge the semi-solid metals.