scholarly journals Numerical investigation on crack analysis of H13 fixed die and structural analysis of moving die with two different materials

2021 ◽  
Vol 6 (1 (114)) ◽  
pp. 81-86
Author(s):  
Hassan Abdurssoul Abdulhadi
Keyword(s):  
Temperature Distribution ◽  
Numerical Analysis ◽  
Magnesium Alloy ◽  
Structural Analysis ◽  
Magnesium Alloys ◽  
Crack Formation ◽  
Die Casting ◽  
Formation Zone ◽  
Strain Relationship ◽  
Aluminum And Magnesium Alloys

Die casting is forcing molten metal into a mould with high pressure. Die casting has two dies namely moving die and fixed die where the moving one will move over the fixed die. Die casting is majorly used for high-volume production. This paper focused on the physical phenomenon of die casting for two dies (moving die and fixed die) using two different alloy materials with variable material chemical compositions. The numerical analysis is carried out for the die casting process to determine the crack formation zone by temperature distribution and structural analysis by stress-strain relationship. The numerical analysis is carried out for both the dies. The fixed die is analyzed with an H13 tool steel material with two moving die materials as aluminum alloy (A356) and magnesium alloy (AZ91D). Both the dies (fixed and moving) were designed by using design software and meshing is carried out followed by analysis using the analysis software. The physical parameter for the dies is applied that is temperature distribution is carried out by applying a temperature of 850 °C and 650 °C over the fixed die for aluminum and magnesium alloy, respectively. Structural analysis is carried out for the moving die with a load of 1,000 N for both aluminum and magnesium alloys with 1000  number of iterations. The results from the numerical analysis are derived and analyzed for both temperature distribution and structural analysis. The crack formation zone is found out by means of temperature gradient and the stress-strain relationship is found out by means of structural analysis. From the results, it was concluded that the crack zone is obtained at 1.22E-10 °C/mm and 6.856E-14 °C/mm of thermal gradient and structural analysis in terms of maximum stress of 446.94 MPa and 448.52 MPa for aluminum and magnesium alloys, respectively.

Development of 2-Cavity Die Casting Process for AM50 Mg Steering Column Lock Housing Module

2006 ◽  
Vol 510-511 ◽  
pp. 334-337
Author(s):  
Shae K. Kim
Keyword(s):  
Magnesium Alloy ◽  
Aluminum Alloys ◽  
Magnesium Alloys ◽  
Weight Reduction ◽  
Die Casting ◽  
Casting Process ◽  
Research Strategy ◽  
Good Choice ◽  
Weight Basis ◽  
Die Casting Process

It is obvious that automotive industry worldwide is predicting significant growth in the use of magnesium alloys for weight reduction to decrease fuel consumption and emission. About a half decade ago, the price of magnesium alloys was more than twice that of aluminum alloys on a weight basis. Currently, magnesium alloys cost about one and a half times that of aluminum alloys on a weight basis, and thus the price of magnesium alloys is the same as or lower than that of aluminum alloys on a per volume basis. However, in considering the performance of magnesium components (not their specific mechanical properties) and recycling aspect of magnesium alloys, it is required to realize niche applications of magnesium alloys, which meet the cost requirement on performance basis and/or offer more than weight reduction. There are many other factors that make magnesium a good choice: component consolidation, improved safety for driver and passengers, and improved noise vibration and harshness (NVH), to name a few. As one of these efforts to adopt magnesium alloys in automotive component, this paper describes the research strategy of cold chamber type 2-cavity die casting of AM50 magnesium alloy for developing the steering column lock housing module with emphasis on cost driving factors and necessities for cost reduction, explaining why AM50 magnesium alloy is chosen with design and die casting process optimization.

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 Mg-Al-RE Magnesium Alloys for High-Pressure Die-Casting

2014 ◽  
Vol 14 (2) ◽  
pp. 49-52 ◽  
Author(s):  
K.N. Braszczyńska-Malik
Keyword(s):  
High Pressure ◽  
Rare Earth ◽  
Magnesium Alloy ◽  
Intermetallic Compound ◽  
Rare Earth Elements ◽  
Magnesium Alloys ◽  
Die Casting ◽  
High Pressure Die Casting ◽  
Cold Chamber ◽  
Pressure Die Casting

Abstract Experimental Mg-Al-RE type magnesium alloys for high-pressure die-casting are presented. Alloys based on the commercial AM50 magnesium alloy with 1, 3 and 5 mass % of rare earth elements were fabricated in a foundry and cast in cold chamber die-casting machines. The obtained experimental casts have good quality surfaces and microstructure consisting of an α(Mg)-phase, Al11RE3, Al10RE2Mn7 intermetallic compound and small amount of α+γ eutectic and Al2RE phases.

Numerical Analysis on Porous Shunt Used in Magnesium Alloy Furnace

2010 ◽  
Vol 102-104 ◽  
pp. 88-92
Author(s):  
Chun Xiang ◽  
Fu Qiang Ying
Keyword(s):  
Numerical Simulation ◽  
Numerical Analysis ◽  
Magnesium Alloy ◽  
Flow Field ◽  
Magnesium Alloys ◽  
Gas Flow ◽  
Simulation Analysis ◽  
Influence Factors ◽  
Gas Consumption ◽  
Gas Flow Field

In this paper , the author analyzed the influence factors of protection gas flow field, then established the model in a design of the optimized protection gas porous shunt, which is used in magnesium alloys furnace, Numerical simulation analysis optimizes the supplying system of protection gas. The shunt improves the uniformity and validity of the gas which is above the magnesium and reduces the gas consumption. The conclusion is that porous shunt usage will further promote the development and application of magnesium alloy in all fields.

scholarly journals Cyclic Tension Test of AZ31 Magnesium Alloy at Elevated Temperature Realized in a Miniaturized Uniaxial Tensile Test Setup

2016 ◽  
Vol 854 ◽  
pp. 112-117
Author(s):  
Sebastian Suttner ◽  
Marion Merklein
Keyword(s):  
Elevated Temperature ◽  
Magnesium Alloy ◽  
Magnesium Alloys ◽  
Elevated Temperatures ◽  
Kinematic Hardening ◽  
Cyclic Behavior ◽  
Uniaxial Tensile ◽  
Uniaxial Tensile Test ◽  
Hardening Behavior ◽  
Aluminum And Magnesium Alloys

The use of new materials, e.g. aluminum and magnesium alloys, in the automotive and aviation sector is becoming increasingly important to reach the global aim of reduced emissions. Especially magnesium alloys with their low density offer great potential for lightweight design. However, magnesium alloys are almost exclusively formable at elevated temperatures. Therefore, material characterization methods need to be developed for determining the mechanical properties at elevated temperatures. In particular, cyclic tests at elevated temperatures are required to identify the isotropic-kinematic hardening behavior, which is important for numerically modeling the springback behavior. In this contribution, a characterization method for determining the cyclic behavior of the magnesium alloy AZ31B at an elevated temperature of 200 °C is presented. The setup consists of a miniaturized tensile specimen and stabilization plates to prevent buckling under compressive load. The temperature in the relevant area is introduced with the help of conductive heating. Moreover, the complex kinematic model according to Chaboche and Rousselier is identified, to map the transient hardening behavior of AZ31B after load reversal, which cannot be modeled with a single Bauschinger coefficient.

scholarly journals Microstructure and Compression Creep Strength of the Newly Developed Magnesium Alloy DieMag422

2014 ◽  
Vol 1019 ◽  
pp. 177-183
Author(s):  
Hajo Dieringa ◽  
Norbert Hort ◽  
Karl Ulrich Kainer
Keyword(s):  
Magnesium Alloy ◽  
Magnesium Alloys ◽  
Creep Strength ◽  
Creep Resistance ◽  
Die Casting ◽  
High Temperature Strength ◽  
Alloying Element ◽  
Compression Creep ◽  
Additional Alloy ◽  
Pressure Die Casting

<p class="TTPAbstract">Magnesium alloys have been finding increasingly more types of application in the automotive and aerospace industries for over twenty years. Despite the fact conventional magnesium alloys have limited high-temperature strength and creep resistance, especially when they contain aluminium as an alloying element. Aluminium is necessary to improve the castability when high-pressure die casting is the favoured process. Applications with higher operating temperatures require additional alloy elements, which form precipitates with the aluminium during solidification and therefore prevent the formation of Mg17Al12, which is responsible for the low creep resistance of magnesium alloys that contain aluminium. The precipitates formed may also strengthen grain boundaries and so improve the creep strength. Barium and calcium were investigated as elements in a magnesium alloy containing aluminium (DieMag422: 4 wt.-% Al, 2 wt.-% Ba, 2 wt.-% Ca). The compression creep strength was compared at 240°C for stresses between 60 and 120 MPa with two commercial creep-resistant magnesium alloys, AE42 and MRI230D. The stress exponents were calculated from the stress dependence of the minimum creep rate. The concept of a threshold stress was applied and true stress exponents ntclose to 5 were found. The new alloy DieMag422 exhibits improved creep strength compared to both commercial alloys and also has proven it is die castable.</p>

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