Study on the Semi-Solid Thixotropic Forging Forming Process for the Low-Carbon Steel Claw Pole

Low-carbon steel has been popularly applied in numerous applications because of its unique features, such as good plasticity, high strength, great hardness, and excellent toughness. Additionally, the semi-solid thixotropic forging forming method has been widely used in light alloys, due to its advantages of low forming force and high forming quality, whereas its application in ferrous materials is still limited. In this study, the semi-solid thixotropic forging forming process is proposed for producing the low-carbon steel claw pole, with the main stages being radial forging deformation, isothermal treatment, and forging forming. The effect of the area reduction rate on the effective strain from the cross sections of the radial-forged metal bar was studied using numerical simulations. The effect of the isothermal holding process on the microstructures of radial-forged billets was investigated, to obtain the ideal semi-solid microstructures. The microstructure and mechanical properties of low-carbon steel claw poles from the thixotropic forging experiment are presented and discussed. It was found that when the area reduction rate was 67%, the effective strain at the edge of the metal bar exceeded 5.0, while the effective strain at the center was above 1.2, indicating an excellent quality of forging for the bar. The optimization of the process parameters for preparing low-carbon steel semi-solid billets with fine and globular microstructures was achieved with an area reduction rate of 67%, an isothermal temperature of 1500 °C, and a duration time of 15 min. Moreover, the low-carbon steel claw pole fabricated with the optimized operating parameters was found fully filled, with a sharp profile and a flat surface, where the yield strength and tensile strength increased by 88.5% and 79.8%, respectively, compared to the starting materials.