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The forming process of thixo-forging alloy Al-7%Si/Al-17%Si was simulated by finite element software Deform-3D. The influences of billets initial temperature and die temperature on composite forming were investigated. Simulation results show that when the initial temperature of the bottom billet is low, the composite interface line is close to the upper surface of middle part, and the bottom is not filled entirely; however, when the initial temperature of the bottom billet is high, the billet temperature and stress at interface were seriously uneven. With the die temperature of die drops, the billets temperature drops fast and the stress increases fast, so the semi-solid forming time becomes inadequate. With the bad inhomogeneity of billet temperature and stress at interface, the lower part of the composite part is filled incompletely. When the initial temperature of top billet is 580 ℃, the initial temperature of bottom billet is 570 ℃, and the die temperature of die is 400 ℃, the thixo-forging is composited entirely and filled fully with constant and even billet temperature and stress at interface, straight interface line in the middle, thin central part of the composite part. The reliability of the simulation was verified by experiments.
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