Rheology Forming Process of Cast Aluminum Alloys with Electromagnetic Applications

2006 ◽  
Vol 116-117 ◽  
pp. 445-448 ◽  
Author(s):  
T.W Kim ◽  
C.G. Kang ◽  
S.S. Kang
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Gas Content ◽  
Cast Aluminum ◽  
Forming Process ◽  
Cast Aluminum Alloys ◽  
Low Pressure Die Casting ◽  
Thin Walled ◽  
Semi Solid ◽  
Pressure Die Casting

This paper focuses on a rheo-forming of arm parts fabricated by an electromagnetic stirring system (EMS). This forming process takes place under high pressure of high pressure die casting and thin-walled casting is possible. Also, the productivity is higher than for low pressure die casting because of the shorter cycle time. Rheo-forming is advantageous because forming is performed in the semi-solid state with laminar flow and the gas content is low, which makes welding possible. Therefore, this paper examines arm parts with EMS and has investigated the mechanical properties after T6 and T5 heat-treatment.

Application of Automobile Lightweight Alloys and the Development of its Die-Casting Technology

2011 ◽  
Vol 308-310 ◽  
pp. 785-789 ◽  
Author(s):  
De Fang Liu ◽  
Jie Tao
Keyword(s):  
Automotive Industry ◽  
Die Casting ◽  
Low Pressure ◽  
Development Trend ◽  
Casting Technology ◽  
Low Pressure Die Casting ◽  
Lightweight Alloys ◽  
Semi Solid ◽  
Pressure Die Casting ◽  
The Development Trend

With the development of lightweight vehicles, lightweight alloy materials has been increasingly used in automotive industry, automobile manufacturers are therefore looking for thinner and stronger materials so that the higher requirements has became a challenge to lightweight alloy die-casting technology. The paper summarized the applications of lightweight alloys in the automotive industry, and the new advances of lightweight alloys die-casting technology, such as low pressure die-casting, semi-solid die casting, oxygenation die-casting and the combination of different die-casting technologies, and discussed the development trend of the lightweight alloy die-casting technology.

scholarly journals Simulation and Experimental Validation of Secondary Dendrite Arm Spacing for AlSi7Mg0.3 Chassis Parts in Low Pressure Die Casting

2021 ◽  
pp. 28-33
Author(s):  
Alberto Vergnano ◽  
Umberto Bergamini ◽  
Daniele Bianchi ◽  
Paolo Veronesi ◽  
Roberto Spagnolo ◽  
...  
Keyword(s):  
Die Casting ◽  
Integrated Design ◽  
Simulation Models ◽  
Production Equipment ◽  
Cast Aluminum ◽  
Secondary Dendrite Arm Spacing ◽  
Dendrite Arm Spacing ◽  
Simulation Techniques ◽  
Low Pressure Die Casting ◽  
Pressure Die Casting

AbstractThe structural properties of cast aluminum parts are strongly affected by the solidification in the production process. The solidification dynamics determines the Secondary Dendrite Arm Spacing (SDAS), directly affecting the structural strength of the alloy. Simulation techniques enable the integrated design of chassis parts and their production equipment. However, in order to effectively predict the SDAS formation, the simulation models need to be investigated and calibrated. The present research investigates the SDAS formation models and identifies a robust relation to be used in Design by Simulation phases for AlSi7Mg0.3 parts.

Addition of Swarf to Produce a Semi-Solid Slurry during High Pressure Die-Casting of AS9U3 Aluminum Alloy

2019 ◽  
Vol 285 ◽  
pp. 271-276
Author(s):  
Hooman Hadian ◽  
M. Haddad-Sabzevar ◽  
Mohammad Mazinani
Keyword(s):  
High Pressure ◽  
Aluminum Alloy ◽  
Solid Fraction ◽  
Die Casting ◽  
Internal Cooling ◽  
High Solid ◽  
Cooling Agent ◽  
High Solid Fraction ◽  
Semi Solid ◽  
Pressure Die Casting

An internal cooling agent is used in rapid slurry forming (RSF) process to produce a high solid fraction slurry for a short period of time. In the process used in this research, the swarf which is known to be a low enthalpy material was added to the melt as the internal cooling agent. During the process, the swarf started to melt and a semi-solid slurry with a relatively high solid fraction was formed. This slurry was formed by exchanging the enthalpies between the low and high enthalpy materials. A commercial Al-Si-Cu alloy, i.e. AS9U3 Aluminum alloy, was used in this investigation. The microscopic examination showed that the Al-Si eutectic colonies start to melt during the melting process of swarf material resulting in the formation of globular Alpha-Al grains due to the multiplication of secondary dendrites arms. The fracture of dendrites arms and the subsequent spheroidization were suggested to be the origin of non-dendritic globular grains in the final microstructure. The amount of primary globular Alpha-phase was measured by the image analysis software. The results showed that during high pressure die-casting of AS9U3 Aluminum alloy using 4 mm thick samples, around 35 percent solid has been formed at the temperature of 580 oC.

scholarly journals Assessment of Mechanisms for Particle Migration in Semi-Solid High Pressure Die Cast Aluminium-Silicon Alloys

2020 ◽  
Vol 4 (2) ◽  
pp. 51
Author(s):  
Madeleine Law ◽  
Christopher Neil Hulme-Smith ◽  
Taishi Matsushita ◽  
Pär G. Jönsson
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Particle Migration ◽  
Silicon Alloys ◽  
High Pressure Die Casting ◽  
Die Cast ◽  
Semi Solid ◽  
Pressure Die Casting ◽  
Saffman Lift Force ◽  
Externally Solidified Crystals

In semi-solid metal high pressure die casting and in conventional high pressure die casting, it is common to find a defect band just below the surface of the component. The formation of these bands is not fully understood. However, there are several theories as how they occur, and it has been suggested that segregation is caused by the migration of aluminium-rich externally solidified crystals. In the present work the formation of these bands is investigated theoretically by reviewing suitable potential mechanisms for the migration of such crystals. Two mechanisms are identified as the most probable: Saffman lift force and the Mukai-Lin-Laplace effect. However, it was not possible to identify which of these two mechanisms acted in the case studies. Further testing is required to identify the mechanism that is causing the migration of the aluminium globules and suitable tests are proposed.

Corrosion Behaviour of the Anodised A356 Aluminium Alloy Produced by the Rheo-High Pressure Die Casting Process

2014 ◽  
Vol 1019 ◽  
pp. 67-73 ◽  
Author(s):  
Levy Chauke ◽  
Kalenda Mutombo ◽  
Gonasagren Govender
Keyword(s):  
High Pressure ◽  
Aluminium Alloy ◽  
Corrosion Behaviour ◽  
Die Casting ◽  
Casting Process ◽  
Optical Microscope ◽  
High Pressure Die Casting ◽  
Semi Solid ◽  
Pressure Die Casting ◽  
A356 Aluminium Alloy

<span><p>Semi-solid metal forming of aluminium alloys has demonstrated the capability to produce near net shaped high integrity components. Anodising of these components for aesthetic and/or improved corrosion resistance is specified by some designers or users of this technology. The corrosion behaviour of fully anodised and partially anodised A356 aluminium alloy plates produced using the CSIR Rheo-High Pressure Die Casting (CSIR-RHPDC) process was investigated using immersion testing in a 3.5% NaCl solution with pH = 7. Optical microscope equipped with image analysis software and scanning electron microscope (SEM) equipped with Energy Dispersive X-ray Spectroscopy (EDS) were used to evaluate the behaviour of the corroded samples. The fully anodised sample showed that the anodised surface displayed some surface degradation. This degradation was more severe on the anodised surface with surface liquid segregation (SLS), but provided sufficient protection to prevent corrosion of the base metal. The partially anodised sample showed severe corrosion of the based metal with the corrosion concentrated in the silicon rich eutectic and SLS regions.</p> <span style="font-family: Times New Roman; font-size: medium;" face="Times New Roman" size="3"> </span>

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.

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