scholarly journals Casting Techniques: An Alternative for Producing Parts with Recycled Al in the Gravity Die Casting Process

2021 ◽  
Author(s):  
Narducci Carlos Jr.
Keyword(s):  
Material Properties ◽  
Die Casting ◽  
Test Procedure ◽  
Casting Process ◽  
Optical Microscope ◽  
Mechanical Tests ◽  
Metal Mold ◽  
Heat Treated ◽  
Die Casting Process ◽  
Size And Morphology

This work applied the grain refinement technique by heterogeneous nucleation and precipitation hardening to investigate the effect of size and morphology of β-Fe particles on Al-Si alloys\' mechanical behavior Fe-critical, inoculated via Nb+B and heat-treated. The samples for the microstructural analyses were produced according to the standard mold, Test Procedure-1 (TP-1) and, analyzed by optical microscope with polarised light and filter plate and differential interference contrast (DIC) and by X-ray energy dispersive spectroscopy (XRD SEM) with EDS detector analyzer. The specimens for the mechanical tests were cast in a metal mold according to ASTM B108. The combined effect of manipulating the studied alloy Al10Si1Fe0.35Mg resulted in reduced and spheroidized β-Fe precipitates with improved mechanical properties in the material. Properties are similar to those achieved by commercially used alloys with engineering applications in structural and safety parts.

Characterization of Magnesium Automotive Components Produced by Super-Vacuum Die Casting Process

2009 ◽  
Vol 618-619 ◽  
pp. 381-386 ◽  
Author(s):  
K. Sadayappan ◽  
W. Kasprzak ◽  
Zach Brown ◽  
L. Quimet ◽  
Alan A. Luo
Keyword(s):  
Die Casting ◽  
Casting Process ◽  
Air Entrainment ◽  
Automotive Components ◽  
Vacuum Die Casting ◽  
Heat Treated ◽  
Conventional Heat Treatment ◽  
Die Casting Process ◽  
Rapidly Solidified ◽  
Pressure Die Casting

Magnesium automotive components are currently produced by high pressure die casting. These castings cannot be heat-treated to improve the strength and ductility mainly due to the casting imperfections such as porosity and inclusions created by the air entrainment during the turbulent mold filing. These imperfections also prevent magnesium components to be used for highly stressed body components. Efforts were made to produce high integrity magnesium castings through a Super-Vacuum Die Casting process. The AZ91D castings were found to have very low porosity and can be heat-treated without blisters. The tensile properties of the castings were satisfactory. The mechanical properties and thermal analysis indicate that the conventional heat treatment procedure needs to be optimized for such thin sectioned and rapidly solidified castings which have very fine microstructures.

Applications of Squeeze Casting for Automobile Parts

2013 ◽  
Vol 773-774 ◽  
pp. 887-893
Author(s):  
Pongsak Dulyapraphant ◽  
Ekkachai Kittikhewtraweeserd ◽  
Nipon Denmud ◽  
Prarop Kritboonyarit ◽  
Surasak Suranuntchai
Keyword(s):  
High Pressure ◽  
Squeeze Casting ◽  
Die Casting ◽  
Solution Treatment ◽  
Casting Process ◽  
High Pressure Die Casting ◽  
Heat Treated ◽  
Automotive Parts ◽  
Die Casting Process ◽  
Pressure Die Casting

With an increasing pressure on automotive weight reduction, the demand on the lighter weight automotive components continues to increase. In recent years, squeeze casting processes have been used with different aluminium alloys to produce high integrity automotive parts. In this study, the indirect squeeze casting processes is adopted to cast a motorcycles component originally produced by a high pressure die casting process using aluminium alloy ADC12. To minimize amount of gas porosity inside squeeze casts, concepts of (1) minimization of ingate velocity along with (2) bottom filling pattern during the die filling, and (3) maximization of intensifications casting pressure are applied. Then parts are casted with both conventional high pressure die casting and indirect squeeze casting processes. Comparative evaluation of mechanical properties was made between HPDC casts and squeeze casts both in as-cast and heat treated conditions. Results from the experiment have shown that squeeze casts can pass the blister test at 490 °C for 2.5 hours. Then, squeeze casts are heat treated by solution treatment at 484 °C for 20 minutes and artificial age at 190 °C for 2.5 hours, respectively. This improves UTS of the heat treated squeeze cast to 254.14 MPa with 1.84% of elongation, while the UTS of as cast condition from both processes is not significantly different.

A Computer-Aided System for Sustainability Analysis for the Die-Casting Process

2012 ◽  
Author(s):  
Princepal Singh ◽  
Jatinder Madan ◽  
Amrik Singh ◽  
Mahesh Mani
Keyword(s):  
Carbon Emissions ◽  
Material Properties ◽  
Energy Use ◽  
Die Casting ◽  
Casting Process ◽  
Shop Floor ◽  
Sustainability Analysis ◽  
Computer Aided ◽  
Die Casting Process ◽  
Casting Industry

Currently available sustainability analysis systems for the die-casting process primarily depend on the material properties and do not account for process information. As a result they are unable to assess or compare the sustainability of parts made using different process plans. In this paper, we propose a new computer-aided system named Sustainability Analyzer for Die-casting Process. Here, we discuss the details of the architecture and the working of the proposed system. We analyze sustainability using three sustainability indicators, namely energy use, solid waste and carbon emissions. The proposed system is verified by comparing results with the actual data measured from the shop floor. The proposed system is beneficial for sustainability analysis comparing different plans alongside material properties, ultimately helping the die-casting industry to reduce carbon emissions and material waste besides improving energy efficiency.

scholarly journals Industrial Semi-Solid Rheocasting of Aluminum A356 Brake Calipers

2011 ◽  
Vol 2011 ◽  
pp. 1-5 ◽  
Author(s):  
U. A. Curle ◽  
J. D. Wilkins ◽  
G. Govender
Keyword(s):  
Die Casting ◽  
Casting Process ◽  
Shot Sleeve ◽  
Process Stability ◽  
X Ray ◽  
Initial Stage ◽  
Heat Treated ◽  
Die Casting Process ◽  
Semi Solid ◽  
Pressure Die Casting

Industrial semi-solid casting trials of aluminum A356 brake calipers were performed over five days with the CSIR-RCS and high-pressure die casting process cell. Consecutive visual passed castings were used as the measure of process stability, and common defects between trials were categorized. Short fill results are erratic and caused by unintended underdosing by the furnace or incomplete billet discharge at the delivery point in the shot sleeve. Cold shuts can be significantly reduced by adjusting the shot control profile. Surface finish defects include surface roughness and staining caused by lubricant burn off. Visual passed castings display none of the above-mentioned external defects. X-ray examination and pressure testing of heat-treated castings from the consecutive visual passed castings show improvement over the five days. These initial-stage industrialization efforts pave the way for process commercialization.

Development of Semi-Solid Die Casting Product Design and Die Design Technology for Aluminium Alloy Clamp

2016 ◽  
Vol 256 ◽  
pp. 334-339 ◽  
Author(s):  
Song Chen ◽  
Fan Zhang ◽  
You Feng He ◽  
Da Quan Li ◽  
Qiang Zhu
Keyword(s):  
Product Design ◽  
Die Casting ◽  
Casting Process ◽  
Die Design ◽  
Thick Wall ◽  
Thin Wall ◽  
Gating System ◽  
Cross Sectional ◽  
Die Casting Process ◽  
Semi Solid

Semi-solid slurry has significantly higher viscosity than liquid metal. This character of fluidity makes product design and die design, such as gating system, overflow and venting system, be different between these two die casting processes. In the present paper, taking a clamp product as an example, analyses the product optimization and die design by comparing the experimental and computational numerical simulation results. For the clamp, product structure is designed to be suitable for characters of SSM die casting process. The gating system is designed to be uniform variation of thickness, making the cross-sectional area uniformly reduce from the biscuit to the gate. This design ensures semi-solid metal slurry to fill die cavity from thick wall to thin wall. Gate position is designed at the thickest location, the gate shape of semi-solid die casting is set to be much bigger than traditional liquid casting. A good filling behaviour can be achieved by aforementioned all these design principles and it will be helpful to the intensification of pressure feeding after filling.

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.

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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