ATM: A Greener Variant of High Pressure Die Casting

2009 ◽  
Vol 618-619 ◽  
pp. 27-31
Author(s):  
Dayalan R. Gunasegaram ◽  
Michel Givord ◽  
Robert G. O'Donnell
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Ghg Emissions ◽  
Raw Material ◽  
Mass Reduction ◽  
Element Analysis ◽  
High Pressure Die Casting ◽  
Casting Technology ◽  
Pressure Die Casting

ATM high pressure die casting technology (ATM) is a variant of the traditional high pressure die casting (HPDC) process and is distinguishable by its characteristic lean runners that increase process yields. Reduced raw material consumption helps ATM leave a smaller footprint on the environment by lowering greenhouse gas (GHG) emissions during primary processing of the alloys and in their melting and handling in the foundry. Further avenues for reducing GHG emissions are raised by the use of ATM technology which improves the integrity of castings - facilitating the adoption of lighter weight components in automobiles. In the present paper, reductions in GHG emissions achieved by ATM are illustrated with the aid of a commercial case study; potential mass reduction opportunities for the automotive sector are explored with the aid of finite element analysis.

scholarly journals Simulation Aspects of the High Pressure Die Casting Process

2019 ◽  
Vol 4 (1) ◽  
pp. 521-529
Author(s):  
Marianna Bubenkó ◽  
Dániel Molnár
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Casting Process ◽  
Raw Material ◽  
Textured Surface ◽  
High Pressure Die Casting ◽  
Shortest Distance ◽  
Surface Metal ◽  
Die Casting Process ◽  
Pressure Die Casting

High pressure die casting (HPDC) is a manufacturing process for producing accurately dimensioned, sharply defined, smooth or textured surface metal parts. It is accomplished by injecting liquid metal at fast velocity and under high pressure into reusable steel dies. Compared to other casting processes, die casting is at the top end of both velocity and pressure. The high velocity translates into a very turbulent flow condition. The process is often described as the shortest distance between raw material and the finished product.

Greenhouse Gas Emissions Attributable to High Pressure Die Casting

2009 ◽  
Vol 618-619 ◽  
pp. 21-26 ◽  
Author(s):  
Ambavalavanar Tharumarajah ◽  
Dayalan R. Gunasegaram ◽  
Paul Koltun
Keyword(s):  
High Pressure ◽  
Magnesium Alloy ◽  
Greenhouse Gas ◽  
Process Parameters ◽  
Die Casting ◽  
Ghg Emissions ◽  
High Pressure Die Casting ◽  
Cycle Times ◽  
Die Castings ◽  
Pressure Die Casting

In spite of die castings being amongst the highest volume items manufactured by the metalworking industry, the influence of high pressure die casting (HPDC) process parameters on greenhouse gas (GHG) emissions remains largely unreported. In this article, the authors discuss the effect of some HPDC process parameters on GHG emissions using cradle-to-gate life cycle assessment (LCA) for both aluminium and magnesium alloys. Although the impacts reduced with increasing yields in both cases, it was determined that the GHG impact of magnesium alloy HPDC was more sensitive to HPDC yield irrespective of the ratio of primary/secondary alloys in the melt charge. The reasons for this include a greater dependence of magnesium alloy HPDC on high-emitting primary processing and the use of the highly potent GHG SF6 for melting. For magnesium alloy HPDC, a decrease in quality assurance (QA) rejects and cycle times also reduced GHG emissions, although their influences were found to be an order lower than that of yield.

scholarly journals Near-Net Forming Complex Shaped Zr-Based Bulk Metallic Glasses by High Pressure Die Casting

Materials ◽  
2018 ◽  
Vol 11 (11) ◽  
pp. 2338 ◽  
Author(s):  
Lehua Liu ◽  
Tao Zhang ◽  
Zhiyuan Liu ◽  
Chunyan Yu ◽  
Xixi Dong ◽  
...  
Keyword(s):  
High Pressure ◽  
Metallic Glasses ◽  
Large Scale ◽  
Die Casting ◽  
Bulk Metallic Glasses ◽  
Dimensional Accuracy ◽  
Raw Material ◽  
High Pressure Die Casting ◽  
Industrial Grade ◽  
Pressure Die Casting

Forming complex geometries using the casting process is a big challenge for bulk metallic glasses (BMGs), because of a lack of time of the window for shaping under the required high cooling rate. In this work, we open an approach named the “entire process vacuum high pressure die casting” (EPV-HPDC), which delivers the ability to fill die with molten metal in milliseconds, and create solidification under high pressure. Based on this process, various Zr-based BMGs were prepared by using industrial grade raw material. The results indicate that the EPV-HPDC process is feasible to produce a glassy structure for most Zr-based BMGs, with a size of 3 mm × 10 mm and with a high strength. In addition, it has been found that EPV-HPDC process allows complex industrial BMG parts, some of which are hard to be formed by any other metal processes, to be net shaped precisely. The BMG components prepared by the EVP-HPDC process possess the advantages of dimensional accuracy, efficiency, and cost compared with the ones formed by other methods. The EVP-HPDC process paves the way for the large-scale application of BMGs.

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