scholarly journals Effect of vacuum system on porous product defects and micro structures on the ADC-12 aluminum material with cold chamber die casting machines

2021 ◽  
Vol 878 (1) ◽  
pp. 012072
Author(s):  
B Budiarto ◽  
T D Kurniawan
Keyword(s):  
Aluminum Alloy ◽  
Hot Spot ◽  
Die Casting ◽  
Casting Machine ◽  
Vacuum System ◽  
Magma Flow ◽  
Alloy Material ◽  
Cold Chamber ◽  
Better Than ◽  
Aluminum Material

Abstract Research on the effect of the vacuum system on porous product defects and microstructure on the ADC-12 aluminum alloy material with cold chamber die casting machine has been carried out. In the injection process in cold chamber die casting, the aluminum material commonly used is namely ADC-12. The ADC-12 aluminum alloy has better resistance to corrosion, is lightweight, has ease of casting, good mechanical properties, and dimensional stability. The purpose of this study is to compare the vacuum system with overflow system using ADC-12 aluminum alloy material with observed parameters are porosity, trapped air pressure, hot spot level, hardness level of Vickers Hardness, XRD analysis, and microstructure analysis with Light Optical Microscope (LOM). The results of the analysis using the Magma flow software, the vacuum system is better than the overflow system in terms of porosity and product yield, which is influenced by the amount of air trapped and the hot spot level. The level of hardness in a product with a vacuum system is better than a product with an overflow system. The average hardness in the vacuum system is 162,235 while in the overflow system is 147,615. Thus, the use of a vacuum system can increase the level of hardness in products by around 9%. With the change in usage from the overflow system to the vacuum system, it shows an increase in dislocation density followed by an increase in lattice strain and a decrease in the level of crystal size of the product.

Newly Developed Heat Resistant Magnesium Alloy by Thixomolding®

2005 ◽  
Vol 488-489 ◽  
pp. 287-290 ◽  
Author(s):  
Tadayoshi Tsukeda ◽  
Ken Saito ◽  
Mayumi Suzuki ◽  
Junichi Koike ◽  
Kouichi Maruyama
Keyword(s):  
Aluminum Alloy ◽  
Magnesium Alloy ◽  
Magnesium Alloys ◽  
Room Temperature ◽  
Elevated Temperatures ◽  
Die Casting ◽  
The Other ◽  
Heat Resistant ◽  
Higher Temperature ◽  
Better Than

We compared the newly developed heat resistant magnesium alloy with conventional ones by Thixomolding® and aluminum alloy by die casting. Tensile properties at elevated temperatures of AXEJ6310 were equal to those of ADC12. In particular, elongation tendency of AXEJ6310 at higher temperature was better than those of the other alloys. Creep resistance of AXEJ6310 was larger than that of AE42 by almost 3 orders and smaller than that of ADC12 by almost 2 orders of magnitude. Fatigue limits at room temperature and 423K of AXEJ6310 was superior among conventional magnesium alloys.

scholarly journals Reduction of Blowholesin Aluminium High Pressure Die Casting Machine

2018 ◽  
Vol 7 (3.34) ◽  
pp. 410
Author(s):  
Nagasankar P ◽  
Sathiyamoorthy. V ◽  
Gurusamy. P ◽  
VinothKanna P ◽  
Manibharathi D ◽  
...  
Keyword(s):  
High Pressure ◽  
Manufacturing Process ◽  
Die Casting ◽  
Casting Machine ◽  
Casting Process ◽  
Magma Flow ◽  
High Pressure Die Casting ◽  
Analysis Technique ◽  
Quality Product ◽  
Pressure Die Casting

The main objective of this research is to reduce the blowholes by analyzing the factors which are affected during the casting process. The process parameters are optimized and change is made in the design part to reduce the blowhole and to increase the efficiency of the high pressure die casting machines. Product manufactured from every manufacturing process shows some defects. For supplying quality product to the customer these defects must be reduced. In this work, an attempt is made to reduce the rejection due to the blowhole defect is found out through why-why analysis technique. Process capability of current high pressure die casting manufacturing process is checked. Manufacturing process found capable to manufacture the components. Current problem of blowhole defect is solved making an improvement in design of die which we insert. In gate directions are changed so as to obtain modified improved flow pattern. Using magma flow simulationsoftware existing and modified design has then been compared. It is found that, modified design shows superior results and using this, the defect of blowholes is minimized up to satisfactory level.   

scholarly journals MOVEMENT OF METALLIC MELT IN A COLD CHAMBER OF A DIE CASTING MACHINE

2017 ◽  
Vol 54 (10) ◽  
pp. 109-113
Author(s):  
Denis Alexandrovich Chemezov ◽  
Keyword(s):  
Die Casting ◽  
Casting Machine ◽  
Metallic Melt ◽  
Cold Chamber

Industrialization of Aluminum Alloy Uniform Solidification Controlled Rheological Die Casting

2022 ◽  
Vol 327 ◽  
pp. 163-171
Author(s):  
Ming Fan Qi ◽  
Yong Lin Kang ◽  
Yuan Hao Zheng ◽  
Ji Cheng Wang ◽  
Gu Nan Li ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Large Volume ◽  
Large Scale ◽  
Die Casting ◽  
Casting Machine ◽  
Semisolid Slurry ◽  
Valve Body ◽  
New Energy ◽  
Thin Walled ◽  
New Energy Vehicles

An efficient and low-cost aluminum alloy uniform solidification control technology, namely, air-cooled stirring rod (ACSR) process, has been developed for preparing large volume semisolid slurry. The semisolid slurry preparation process is connected with the die-casting machine to form multiple integrated intelligent rheological die-casting production lines for the efficient preparation of rheological die-casting of large-scale thin-walled aluminum alloys. At present, the ACSR process can produce 40 kg of large-volume semisolid slurry with a solid phase ratio of 25% to 35% within 30 s. This rheological die-casting process has been industrialized for the preparation of high-quality aluminum alloy large-scale thin-walled parts, such as new energy vehicles and 5G communications. Typical products produced by this process include heat dissipation housings for 5G communications, filter housings, antenna chassis and three-electric structural shell, end cover, and ABS system valve body for new energy vehicles. Compared with traditional die castings, aluminum alloy castings prepared by the new process not only have fine and spherical microstructures, good surface quality, and fewer internal pores but also enjoys more excellent mechanical properties and thermal conductivity.

scholarly journals Porosity of Castings Produced by the Vacuum Assisted Pressure Die Casting Method

2015 ◽  
Vol 15 (1) ◽  
pp. 125-130 ◽  
Author(s):  
A. Zyska ◽  
Z. Konopka ◽  
M. Łągiewka ◽  
M. Nadolski
Keyword(s):  
Negative Pressure ◽  
Elevated Temperatures ◽  
Die Casting ◽  
Casting Machine ◽  
Vacuum System ◽  
Relative Pressure ◽  
Technological Parameters ◽  
Absolute Value ◽  
The Absolute ◽  
Pressure Die Casting

Abstract The paper presents the results of investigations concerning the influence of negative (relative) pressure in the die cavity of high pressure die casting machine on the porosity of castings made of AlSi9Cu3 alloy. Examinations were carried out for the VertaCast cold chamber vertical pressure die casting machine equipped with a vacuum system. Experiments were performed for three values of the applied gauge pressure: -0.3 bar, -0.5 bar, and -0.7 bar, at constant values of other technological parameters, selected during the formerly carried initial experiments. Porosity of castings was assessed on the basis of microstructure observation and the density measurements performed by the method of hydrostatic weighing. The performed investigation allowed to find out that - for the examined pressure range - the porosity of castings decreases linearly with an increase in the absolute value of negative pressure applied to the die cavity. The negative pressure value of -0.7 bar allows to produce castings exhibiting porosity value less than 1%. Large blowholes arisen probably by occlusion of gaseous phase during the injection of metal into the die cavity, were found in castings produced at the negative pressure value of -0.3 bar. These blowholes are placed mostly in regions of local thermal centres and often accompanied by the discontinuities in the form of interdendritic shrinkage micro-porosity. It was concluded that the high quality AlSi9Cu3 alloy castings able to work in elevated temperatures can be achieved for the absolute value of the negative pressure applied to the die cavity greater than 0.5 bar at the applied set of other parameters of pressure die casting machine work.

Casting Mold Designing for Aluminum Alloy Car Holders

2013 ◽  
Vol 378 ◽  
pp. 350-354
Author(s):  
Xue Dong Wang ◽  
Jian He Lin ◽  
Suo Qing Yu ◽  
Li Yong Ni
Keyword(s):  
Aluminum Alloy ◽  
Die Casting ◽  
Casting Machine ◽  
Bottom Surface ◽  
Gating System ◽  
Process Scheme ◽  
Molding Process ◽  
Casting Mold ◽  
Machine Mold ◽  
Die Castings

The structure and processing of car holders castings were analyzed. Die-casting molding process scheme was established. The design of mold includes three core-drawing mechanisms. the gate of the gating system was arranged on the casting bottom surface. For economy and die easy maintenance considerations, die-casting machine, mold, and mold standard parts should be standard parts. The designs of mold gating system and non-standard pieces were completed with the aid of PROE. Proved by actual production, the mold operated smoothly, without clamping stagnation, and the production of die castings meet delivery requirements.

scholarly journals Shape Mapping Detection of Electric Vehicle Alloy Defects Based on Pulsed Eddy Current Rectangular Sensors

2018 ◽  
Vol 8 (11) ◽  
pp. 2066 ◽  
Author(s):  
Kai Zhang ◽  
Zhurong Dong ◽  
Zhan Yu ◽  
Yunze He
Keyword(s):  
Aluminum Alloy ◽  
Magnetic Flux ◽  
Electric Vehicle ◽  
Eddy Current ◽  
Comparison Of Results ◽  
Pulsed Eddy Current ◽  
Alloy Material ◽  
Plane Shape ◽  
Shape Mapping ◽  
Better Than

In this paper, we investigate pulsed eddy current (PEC) testing based on a rectangular sensor for the purpose of defect shape mapping in electric vehicle lightweight alloy material. Different dimensional defects were machined on the 3003 aluminum alloy and detected using the A-scan technique and C-scan imaging in two scanning directions. The experiment results indicated that defect plane shape could be preliminarily obtained and length and width could be estimated based upon C-scan contour images. Consequently, the comparison of results between the two directions showed that the C-scan identification in the direction of magnetic flux was better than in the direction of the exciting current. Finally, subsurface defects and irregular defects were detected to verify the performance of shape mapping as a recommended approach. The conclusion drawn indicates that the proposed method, based on PEC rectangular sensors, is an effective approach in reconstructing a defect’s shape.

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