Considerations on the Reliability of Advanced Squeeze Casting Process

2012 ◽  
Vol 504-506 ◽  
pp. 361-366
Author(s):  
Mario Rosso ◽  
Ildiko Peter
Keyword(s):  
High Performance ◽  
Fracture Behavior ◽  
Squeeze Casting ◽  
Casting Process ◽  
Standard Samples ◽  
Heat Treated ◽  
Semi Solid ◽  
Non Destructive ◽  
Squeeze Casting Process ◽  
A380 Alloys

This paper presents an analysis of an advanced squeeze casting process suitable for the manufacturing of high performance industrial components more quickly and cheaply. After a short description of the process, some produced components are considered. The components, in A380 alloys, have been T6 heat treated and their soundness has been certified by non destructive tests. All considered components have been designed for advanced application in the automotive field, in particular for quite important sport cars. Standard samples for tensile and impact tests have been machined directly from the previous components. After the execution of the tests the fracture surface of samples has been observed by SEM in order to analyze details and to evaluate the influence of the process and of the alloy on the fracture behavior. On polished transverse sections of samples the microstructure of the alloy has been observed, highlighting a mainly globular shaped microstructure as expression of the attained semi-solid conditions during the processes. A critical analysis has been developed to evaluate the real potential and to present some criticism of the process.

Development of Steel Wire Rope – Reinforced Aluminium Composite for Armour Material Using the Squeeze Casting Process

2011 ◽  
Vol 277 ◽  
pp. 27-35 ◽  
Author(s):  
Dwi Rahmalina ◽  
Bondan Tiara Sofyan ◽  
Bambang Suharno ◽  
Eddy S. Siradj
Keyword(s):  
Squeeze Casting ◽  
Steel Wire ◽  
High Carbon Steel ◽  
Casting Process ◽  
Optical Microscope ◽  
Wire Rope ◽  
Aluminium Composite ◽  
Ballistic Properties ◽  
Semi Solid ◽  
Squeeze Casting Process

Steel wire rope – reinforced aluminium composite - has been developed to improve the ballistic properties and mobility of armour material. Critical to obtaining ballistic resistance is that the materials must be sufficiently hard and strong, especially at the surface where a projectile will first make impact. To obtain this resistance, aluminium alloys can be strengthened by adding Cu and Mg. This research studied the ballistic properties of aluminium composites with varied Cu and Mg content. The matrix used in this study was an Al-7Si master alloy with 0.08-1.03 wt. % Mg and 0.05-3.75 wt. % Cu, both independently and in combination. A high carbon steel wire rope was used as strengthening material. The samples were produced through the squeeze casting process with a pressure of 1 MPa at semi-solid melting temperatures of 590-610 °C. The slab was then rolled for 10 % reduction to increase the hardness. Ballistic testing was performed in accordance with ASTM F1233 by using a 9 mm calibre projectile and 900 direction. Micro structural observation was conducted in the as-cast and ballistic samples, performed with optical microscope and scanning electron microscope (SEM). The results showed that squeeze casting may improve interfacial wettability and reduce void. The increase in Mg resulted in the decline of interfacial voids, but Cu addition tended to increase them. The aluminium armour was able to withstand a 9 mm calibre projectile, although some cracks were visible. The wire rope was not effective in stopping the penetration of a 7.62 mm calibre projectile.

Die Design for Main Bearing Cap of Engine Block Based Semi-Solid Die Casting Process and the Comparison Analysis with Squeeze Casting Process

2019 ◽  
Vol 285 ◽  
pp. 429-435 ◽  
Author(s):  
Song Chen ◽  
Da Quan Li ◽  
Fan Zhang ◽  
Min Luo ◽  
Xiao Kang Liang ◽  
...  
Keyword(s):  
Squeeze Casting ◽  
Die Casting ◽  
Dendritic Structure ◽  
Casting Process ◽  
Die Design ◽  
Main Bearing ◽  
Block Based ◽  
Semi Solid ◽  
Bearing Cap ◽  
Squeeze Casting Process

There are two new processes to development automobile structural components which have certain thickness. In the present paper, taking a main bearing cap product as an example, analyses die design by comparing the experimental and computational numerical simulation results. For the main bearing cap, product structure and mold design were designed to be suitable for characters of SSM die casting and squeeze process. Semi-solid slurry has significantly higher viscosity than liquid metal. This character of fluidity and solid fraction phase make the flow condition more laminar than liquid squeeze casting with the partial fill experiment. And compared with squeeze casting process, the globular shape grain size is smaller than dendritic structure. And mechanical property result shows that the elongation of SSM die casting can achieve more than twice than squeeze casting.

Semi-solid squeeze casting process of a ZL109 alloy

Rare Metals ◽  
2008 ◽  
Vol 27 (3) ◽  
pp. 329-334 ◽  
Author(s):  
Y ZHAI ◽  
C LIU ◽  
Z HAN ◽  
K WANG
Keyword(s):  
Squeeze Casting ◽  
Casting Process ◽  
Semi Solid ◽  
Squeeze Casting Process

Influence of Ti to the Microstructure and Mechanical Properties of Al-12Si-3.2Cu-1Mg-2.4Ni Piston Alloy

2013 ◽  
Vol 477-478 ◽  
pp. 1278-1283
Author(s):  
Ling Zhan Zhou ◽  
Yin Jiang Peng ◽  
Xiu Rong Zhu ◽  
Guang Ming Zhang ◽  
Li Ming Yang ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Grain Size ◽  
Tensile Strength ◽  
Squeeze Casting ◽  
Casting Process ◽  
Optical Microscope ◽  
Heat Treated ◽  
Eutectic Si ◽  
Squeeze Casting Process ◽  
Ti Addition

Al-12Si-3.2Cu-1Mg-2.4Ni-χTi (χ=0, 0.2) alloys were prepared by squeeze casting process, and then heat-treated. The mechanical properties were tested at 350°C, the microstructure and phases in them were investigated by optical microscope, SEM, EDS and XRD. It is found that the grain size has an obvious increment after 0.2 wt. % Ti additions to Al-12Si-3.2Cu-1Mg-2.4Ni, and the ultimate tensile strength at elevated-temperature increased accordingly. Intermetallic compounds, such as γ-Al7Cu4Ni, M-Mg2Si, Q-Al5Cu2Mg8Si6 and δ-Al3CuNi existing in alloys with and without Ti addition. Needle-like Ti containing phase with the elements of Al, Si and Ti created in Al-12Si-3.2Cu-1Mg-2.4Ni-0.2Ti alloy, and the eutectic Si is found to distribute by the side of Ti containing phase.

Study of the Mechanical Properties for an Automotive Part under Squeeze Casting Process

2012 ◽  
Vol 602-604 ◽  
pp. 1837-1845
Author(s):  
Surasak Suranuntchai ◽  
Ekkachai Kittikhewtraweeserd
Keyword(s):  
Mechanical Properties ◽  
Laminar Flow ◽  
Squeeze Casting ◽  
Casting Process ◽  
Primary Study ◽  
Gas Porosity ◽  
Heat Treated ◽  
Automotive Part ◽  
Pressure Die Casting ◽  
Squeeze Casting Process

Squeeze casting is process capable to produce high integrity parts. To minimize gas porosity, melt front’s speed must be kept as minimum as possible to ensure the laminar flow pattern with adequate flow rate to be able to fill the cavity before liquid metal is solidified. In this study, the indirect squeeze casting process was adopted to cast a motorcycle’s component originally produced by a high pressure die casting (HPDC) process. Based on shape and dimension of the parts to get the real castings for the mass production, melt’s speed must be higher than the level reported by the literatures (around 1 m/sec). As a result, a fully laminar flow may not be achievable. This is confirmed by the primary study of the process parameters and tooling design using the casting process simulation. Castings from two processes were casted and then mechanically and micro-structurally compared for both as cast and heat treated conditions. Results from the experiment have shown that size of gas porosity found in squeeze casts reduced significantly, while gain size of the squeeze casts trended to be bigger than that of HPDC casts. In terms of the mechanical properties, the ultimate tensile strength of as cast from both processes was not significantly different, while the heat treated squeeze casts has shown the big improvement compared with the as casts.

scholarly journals Research on Pressure Loss and Filling Ability of Semi-Solid Rheological Behavior in Squeeze Casting

2021 ◽  
Author(s):  
Ying Wang ◽  
Xiaohui Ao
Keyword(s):  
Temperature Distribution ◽  
Rheological Behavior ◽  
Pressure Loss ◽  
Squeeze Casting ◽  
Theoretical Calculations ◽  
Casting Process ◽  
Squeeze Pressure ◽  
Filling Ability ◽  
Semi Solid ◽  
Squeeze Casting Process

Abstract The filling ability of alloy fluid under pressure is of great significance to improve the dimensional integrity and mechanical properties of thin-walled and slender rods formed by squeeze casting. Insight into the rheological behavior of squeeze casting is beneficial to improve the formability of complex structural parts by optimizing the squeeze casting process. In this work, the Archimedes spiral sample prepared by indirect squeeze casting was applied to investigate the variation of filling length with squeeze pressure and filling speed during the rheological process in squeeze casting. According to the temperature distribution characteristic during the alloy melt filling process, the alloy fluid state was discussed and the spiral filling was confirmed as a semi-solid rheological behavior. The calculation models of pressure loss and filling length were established respectively based on steady-state rheological behavior. Pressure loss is mainly affected by the melt viscosity which is determined by temperature distribution and filling speed of alloy melt in the channel. According to the agreement between the theoretical calculations and the experimental results, the pressure loss and filling length models have been confirmed to be used to quantitatively characterize the filling ability of the aluminum alloy melt in the squeeze casting process.

Effects of Nano Particles on the Microstructure of LM 25 (A356) Alloy Manufactured by Squeeze Casting

2017 ◽  
Vol 867 ◽  
pp. 64-70
Author(s):  
N. Nagendran ◽  
N. Gayathri ◽  
V.K. Shanmuganathan ◽  
S. Praveen
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Treatment Process ◽  
Squeeze Casting ◽  
Casting Process ◽  
Nano Particles ◽  
Heat Treatment Process ◽  
Cast Part ◽  
Heat Treated ◽  
Squeeze Casting Process

Conventional casting process cannot produce parts as strong as forged parts. Also there are chances of many casting defects such as porosity, hot tears, shrinkage, pin holes, blow holes, mould shift flash, slag, short casting, when casting method is used for fabrication. Thus cast parts only have low mechanical properties. Recent trend is to use Squeeze Casting, which results in superior mechanical and casting properties. This technique is a hybrid metal forming process combining features of both casting and forging in one operation. This process is suitable for low melting alloys like iron and nickel with mechanical properties enhancement. Reduction in micro porosity in cast part and also reduction in machining. Historically, the series of LM were developed for high strength, corrosion resistance, and good machinability for many applications. In this study Squeeze Casting process has been used, since it has porosity free equiaxed grain components of LM 25 composition and cylindrical shaped castings were manufactured successfully by squeeze casting machine at high temperature and high pressure. The first part of the study is about the microstructure of the LM 25 Al-7 Si-0.3 Mg-0.5 Fe alloy. The casting products were made by addition of nano particles and without nano particles. The size of bar casted was by squeeze casting process. It was 260 mm*46mm (7 Pieces). Microstructure of Cast without squeeze and without stirrer, without squeeze and with stirrer, with squeeze and with stirrer Alloys was studied. The second part of the work was the heat treatment process of the finished product. Heat treatment process was conducted at 490○C and for the heat treated metals was quenched at 30○C (water) for the heat treated and unheated metal casting product were taken and microstructure were studied. The results were compared before and after the heat treatment process for addition of nano particles and without nano particles.

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