Aluminum Casting Processes

2004 ◽  
pp. 21-37
Keyword(s):  
Metal Matrix ◽  
Historical Development ◽  
Die Casting ◽  
Hot Isostatic Pressing ◽  
Casting Process ◽  
Matrix Composites ◽  
Metallurgical Bonding ◽  
Alloy Castings ◽  
Pressure Die Casting ◽  
Selection Of

Abstract This chapter begins with information on the historical development of aluminum alloy castings. It then covers the basic factors involved in the selection of a casting process. This is followed by sections describing the various categories of casting processes and their variants: expendable mold gravity-feed casting, nonexpendable (permanent) mold gravity feed casting, and pressure die casting. Next, the chapter describes the technologies used to produce premium engineered castings and when such castings may be relevant. The chapter concludes with descriptions of other process technologies used with castings, including metallurgical bonding, metal-matrix composites, and hot isostatic pressing.

A Design Optimization of the High Pressure Die Casting Process for the Fabrication of Bulk Metal Matrix Composites

2017 ◽  
Vol 6 (1) ◽  
pp. 20170052
Author(s):  
B. O. Malomo ◽  
O. T. Ogunbodede ◽  
O. T. Popoola ◽  
K. M. Oluwasegun ◽  
S. A. Ibitoye ◽  
...  
Keyword(s):  
High Pressure ◽  
Design Optimization ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Die Casting ◽  
Casting Process ◽  
Matrix Composites ◽  
Bulk Metal ◽  
Die Casting Process ◽  
Pressure Die Casting

Semi-Solid High Pressure Die Casting of Metal Matrix Composites Produced by Liquid State Processing

2012 ◽  
Vol 192-193 ◽  
pp. 61-65 ◽  
Author(s):  
Lilian Ivanchev ◽  
Sigqibo Templeton Camagu ◽  
Gonasagren Govender
Keyword(s):  
High Pressure ◽  
Solid State ◽  
Metal Matrix Composites ◽  
Liquid State ◽  
Metal Matrix ◽  
Die Casting ◽  
Matrix Composites ◽  
Semi Solid ◽  
Pressure Die Casting ◽  
State Processing

There are two main technologies for manufacturing of particulate reinforced metal matrix composites (MMC), solid state and liquid state processing. The great challenge of producing cast metal matrix composites is to prevent agglomeration of particulates. This tendency is more pronounced with decreasing the particulate size to fine micro- and nano size. A method for producing MMC was successfully implemented for mixing hybrid, nano and low micron sized, reinforcing particles in an aluminium alloy matrix. The hybrid SiC particles were produced by milling 3µm to 5µm SiC particles to a particle size range between 2.5µm and 150 nm. The hybrid particles were mixed with A356 aluminium alloy under combined magneto-hydrodynamic (MHD) and mechanical stirring. The composite was then transferred to a High Pressure Die Casting (HPDC) machine in the semi-solid state. The micron size particles were found to be predominantly in the intergranular eutectic while the nano-particles were predominantly in the primary α-Al grains. Increased ultimate tensile strength, yield strength and hardness were achieved for the new cast metal matrix hybrid component (MMHC) alloy.

CFD Simulation and Experimental Validation of Solidification of Metal Matrix Composites (MMC) in the Presence of Cooled Fibers

2004 ◽  
Author(s):  
R. S. Amano ◽  
J. Xie ◽  
E. K. Lee ◽  
P. K. Rohatgi
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Cfd Simulation ◽  
Applied Pressure ◽  
Casting Process ◽  
Processing Parameters ◽  
Matrix Composites ◽  
Primary Alpha ◽  
Parametric Studies ◽  
Solidification Of Metal

A new experimental configuration for the casting of metal matrix composites (MMCs) using Al-4.5 wt pct Cu have been used to obtain finer microstructures around the fiber reinforcement. The new configuration allows the fibers to be extended out the mold and cooled by a heat sink. By doing so, the solidification can be made more rapid, and more primary alpha-aluminum phase can be formed on the surface of the fibers. It is believed that this can lead to improvement in the properties of the composite. CFD simulation of the solidification of Al-4.5 wt pct Cu in the casting process has been carried out by using commercial CFD code. Parametric studies on the effects of different processing parameters on solidification time have been simulated using the CFD code. These parameters include, but are not limited to, the pouring temperature of the liquid melt, sink temperature, fiber length extended out of the mold, the mold initial temperature, fiber conductivity, applied pressure, and fiber bundle diameter. Selected simulation results are compared with the available experimental data obtained from the UWM Center for Composites.

Predicting heat extraction due to boiling in the cooling channels during the pressure die casting process

2000 ◽  
Vol 214 (3) ◽  
pp. 465-482 ◽  
Author(s):  
L D Clark ◽  
I Rosindale ◽  
K Davey ◽  
S Hinduja ◽  
P J Dooling
Keyword(s):  
Heat Transfer ◽  
Forced Convection ◽  
Die Casting ◽  
Casting Process ◽  
Nucleate Boiling ◽  
Heat Extraction ◽  
Film Boiling ◽  
Cooling Channels ◽  
Die Casting Process ◽  
Pressure Die Casting

The effect of boiling on the rate of heat extraction by cooling channels employed in pressure die casting dies is investigated. The cooling effect of the channels is simulated using a model that accounts for subcooled nucleate boiling and transitional film boiling as well as forced convection. The boiling model provides a continuous relationship between the rate of heat transfer and temperature, and can be applied to surfaces where forced convection, subcooled nucleate boiling and transitional film boiling are taking place in close proximity. The effects of physical parameters such as flow velocity, degree of subcooling, system pressure and bulk temperature are taken into account. Experimental results are obtained using a rig that simulates the pressure die casting process. The results are compared with the model predictions and are found to show good agreement. Instrumented field tests, on an industrial die casting machine, are also reported. These tests show the beneficial effects of boiling heat transfer in the pressure die casting process, including a 75 per cent increase in the production rate for the test component.

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