Predicting grain structure in high pressure die casting of aluminum alloys: A coupled cellular automaton and process model

2019 ◽  
Vol 161 ◽  
pp. 64-75 ◽  
Author(s):  
Cheng Gu ◽  
Yan Lu ◽  
Emre Cinkilic ◽  
Jiashi Miao ◽  
Andrew Klarner ◽  
...  
Keyword(s):  
High Pressure ◽  
Aluminum Alloys ◽  
Cellular Automaton ◽  
Process Model ◽  
Die Casting ◽  
Grain Structure ◽  
High Pressure Die Casting ◽  
Pressure Die Casting

Influence of Process Parameters on the Fluidity of High Pressure Die-Casting Al-Si Alloys

2013 ◽  
Vol 813 ◽  
pp. 171-174
Author(s):  
Young Chan Kim ◽  
Se Weon Choi ◽  
Cheol Woo Kim ◽  
Jae Ik Cho ◽  
Chang Seog Kang
Keyword(s):  
High Pressure ◽  
Aluminum Alloys ◽  
Treatment Time ◽  
Die Casting ◽  
Influence Of Process Parameters ◽  
Vacuum Suction ◽  
Gravity Casting ◽  
High Pressure Die Casting ◽  
Injection Speed ◽  
Pressure Die Casting

It is generally known that silicon influences the fluidity of aluminum alloys. There are several techniques to evaluate the fluidity of aluminum for gravity casting such as using spiral or serpentine type mold and vacuum suction test. However, fluidity of aluminum in high pressure die-casting has not been sufficiently studied. Therefore, in this study, the relationship between the fluidity and superheat of pouring aluminum alloy as well as injection speed was studied. A serpentine and step type die for evaluating the fluidity of aluminum alloys was designed and actual experiments were conducted for aluminum by varying many parameters such as pouring and injection speed and the content of silicon. The results showed that fluidity of aluminum in die-casting was quite similar to the gravity casting. Under high pressure die casting conditions, increased fluidity was measured as the silicon content, superheat, G.B.F treatment time and injection speed were increased.

scholarly journals Novel Magnesium Based Materials: Are They Reliable Drone Construction Materials? A Mini Review

2021 ◽  
Vol 8 ◽  
Author(s):  
Daniel Höche ◽  
Wolfgang E. Weber ◽  
Eugen Gazenbiller ◽  
Sarkis Gavras ◽  
Norbert Hort ◽  
...  
Keyword(s):  
High Pressure ◽  
Aluminum Alloys ◽  
Magnesium Alloys ◽  
Elevated Temperatures ◽  
Construction Material ◽  
Die Casting ◽  
Next Generation ◽  
High Pressure Die Casting ◽  
Aerial Vehicles ◽  
Pressure Die Casting

Novel magnesium-based materials are ideal candidates for use in future aviation vehicles because they are extremely light and can therefore significantly increase the range of these vehicles. They show very good castability, are easy to machine and can be shaped into profiles or forgings to be used as components for next generation aerial vehicle construction. In the case of a large number of identical components, high-pressure die casting of magnesium alloys is clearly superior to high-pressure die casting of aluminum alloys. This is due to the lower solubility of iron in magnesium and thus tool/casting life is significantly longer. In addition, the die filling times for magnesium high-pressure die casting are approximately 30% shorter. This is due to the lower density: aluminum alloys are approximately 50% heavier than magnesium alloys, which is a significant disadvantage for aluminum alloys especially in the aerospace industry. There are cost-effective novel die casting alloys, besides AZ91 or AM50/60 such as DieMag633 or MRI230D, which show very good specific strength at room and elevated temperatures. In the case of magnesium-based wrought alloys, the choice is smaller, a typical representative of these materials is AZ31, but some new alloys based on Mg-Zn-Ca are currently being developed which show improved formability. However, magnesium alloys are susceptible to environmental influences, which can be eliminated by suitable coatings. Novel corrosion protection concepts for classical aerial vehicles currently under development might suitable but may need adaption to the construction constraints or to vehicle dependent exposure scenarios. Within this mini-review a paradigm change due to utilization of new magnesium materials as drone construction material is briefly introduced and future fields of applications within next-generation aerial vehicles, manned or unmanned, are discussed. Possible research topics will be addressed.

A Development of Virtual Manufacturing System for Magnesium High Pressure Die Casting Processes

Materials ◽  
2003 ◽  
Author(s):  
Weilong Chen
Keyword(s):  
High Pressure ◽  
Magnesium Alloys ◽  
Die Casting ◽  
Virtual Manufacturing ◽  
Mold Design ◽  
High Pressure Die Casting ◽  
Molten Magnesium ◽  
Pressure Die Casting ◽  
Soft And Hardware ◽  
Free Magnesium

In recent years, high-pressure die-casting magnesium components have been gaining currency worldwide because of the excellent properties that magnesium alloys can offer to meet new product requirements. With the increasing application of magnesium parts worldwide, many research and development projects have been carried out to advance HPDC technology. However, truly optimized mold design and production of defect free castings remains a challenge for die casters. For many HPDC magnesium products, especially those specified for porosity-free and high cosmetic requirement, the challenge not only comes form a lack of a deeper understanding of how molten magnesium alloys fill the mold cavity and form defects, but also from improper preliminary part design. This study proposes a virtual prototyping system that integrates several effective soft and hardware tools for both the part and mold-design engineer to evaluate part manufacturability. Also, investigated in this study are the major causes of those defects that are the predominant cause of rejection of thin walled, leak-free magnesium parts requiring highly cosmetic finishes.

scholarly journals On the Use of Conformal Cooling in High-Pressure Die-Casting and Semisolid Casting

Technologies ◽  
2021 ◽  
Vol 9 (2) ◽  
pp. 39
Author(s):  
Anders E. W. Jarfors ◽  
Ruslan Sevastopol ◽  
Karamchedu Seshendra ◽  
Qing Zhang ◽  
Jacob Steggo ◽  
...  
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Life Extension ◽  
Conformal Cooling ◽  
High Pressure Die Casting ◽  
Cooling Channels ◽  
Die Life ◽  
Die Materials ◽  
Pressure Die Casting ◽  
Semisolid Casting

Today, tool life in high pressure die casting (HPDC) is of growing interest. A common agreement is that die life is primarily decided by the thermal load and temperature gradients in the die materials. Conformal cooling with the growth of additive manufacturing has raised interest as a means of extending die life. In the current paper, conformal cooling channels’ performance and effect on the thermal cycle in high-pressure die casting and rheocasting are investigated for conventional HPDC and semisolid processing. It was found that conformal cooling aids die temperature reduction, and the use of die spray may be reduced and support the die-life extension. For the die filling, the increased temperature was possibly counterproductive. Instead, it was found that the main focus for conformal cooling should be focused to manage temperature around the in-let bushing and possibly the runner system. Due to the possible higher inlet pressures for semisolid casting, particular benefits could be seen.

Failure analysis of H13 steel die for high pressure die casting Al alloy

2021 ◽  
pp. 105330
Author(s):  
Rengen Ding ◽  
Haibo Yang ◽  
Shuzhi Li ◽  
Guodong Wu ◽  
Jiahao Mo ◽  
...  
Keyword(s):  
High Pressure ◽  
Failure Analysis ◽  
Die Casting ◽  
Al Alloy ◽  
H13 Steel ◽  
High Pressure Die Casting ◽  
Pressure Die Casting

scholarly journals A digital twin approach to predict and compensate distortion in a High Pressure Die Casting (HPDC) process chain

2020 ◽  
Vol 52 ◽  
pp. 144-149
Author(s):  
Alireza Ebrahimi ◽  
Udo Fritsching ◽  
Michael Heuser ◽  
Dirk Lehmhus ◽  
Adrian Struß ◽  
...  
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Process Chain ◽  
High Pressure Die Casting ◽  
Digital Twin ◽  
Pressure Die Casting
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