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Laukli, Hans Ivar. "High Pressure Die Casting of Aluminium and Magnesium Alloys : Grain Structure and Segregation Characteristics." Doctoral thesis, Norwegian University of Science and Technology, Department of Materials Technology, 2004. http://urn.kb.se/resolve?urn=urn:nbn:no:ntnu:diva-379.
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Cold chamber high pressure die casting, (HPDC), is an important commercial process for the production of complex near net shape aluminium and magnesium alloy castings. The work presented in the thesis was aimed at investigating the microstructure formation in this type of casting. The solidification characteristics related to the process and the alloys control the formation of grains and defects. This again has a significant impact on the mechanical properties of the castings.
The investigations were carried out mainly using the AM60 magnesium alloy and the A356 aluminium alloy. Two different casting arrangements were used: the cold chamber HPDC and the gravity die casting methods, which allowed for different flow and solidification conditions. The microstructures in the castings were investigated using optical microscopy, image analysis, scanning electron microscopy, electron back scatter diffraction measurements and electron probe microanalysis.
In the HPDC experiments, the shot sleeve solidification conditions were investigated primarily by changing the melt superheat on pouring. This significantly affected the microstructures in the castings. The fraction of externally solidified crystals (ESCs) was consistently found to be largest near the gate in both the AM60 and the A356 die castings. This was attributed to the inherent shot sleeve solidification conditions and the flow set up by the plunger movement. When the superheat was increased, a lower fraction of ESCs was found in the castings. Furthermore, a high superheat gave ESCs with branched dendritic/elongated trunk morphology whilst a low superheat generated coarser and more globular ESCs, both in the AM60 and the A356 castings. The ESCs typically segregated towards the central region of the cross sections at further distances from the gate in the die castings.
When a thin layer of thermal insulating coating was applied on the shot sleeve wall in the production of AM60 die castings, it nearly removed all ESCs in the castings. Using an A356 alloy, (and no shot sleeve coating), with no Ti in solution gave a significantly lower fraction of ESCs, whereas AlTi5B1 grain refiner additions induced an increase in the fraction of ESCs and a significantly finer grain size in the castings. The formation of globular ESCs was enhanced when AlTi5B1 grain refiner was added to the A356 alloy.
In controlled laboratory gravity die casting experiments, typical HPDC microstructures were created by pouring semi-solid metal into a steel die: The ESCs were found to segregate/migrate to the central region during flow, until a maximum packing, (fraction of ESCs of ~35-40%), was reached. The extent of segregation is determined by the fraction of ESCs, and the die temperature affects the position of the ESCs. The segregation of ESCs was explained to occur during flow as a result of lift forces.
The formation of banded defects has also been studied: the position of the bands was affected by the die temperature and the fraction of ESCs. Based on the nature of the bands and their occurrence, a new theory on the formation of defect bands was proposed: During flow the solid distribution from the die wall consists of three regions: 1) a solid fraction gradient at the wall; 2) a low solid fraction region which carries (3) a network of ESCs. A critical fraction solid exists where the deformation rate exceeds the interdendritic flow rate. When the induced stress exceeds the network strength, deformation can occur by slip, followed by liquid flow. The liquid flow is caused by solidification shrinkage, hydrostatic pressure on the interior ESC network, and gaps forming which draw in liquid.
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Roberts, Michael John, and edu au jillj@deakin edu au mikewood@deakin edu au wildol@deakin edu au kimg@deakin. "A Modified Life Cycle Inventory of Aluminium Die Casting." Deakin University. School of Engineering and Technology, 2003. http://tux.lib.deakin.edu.au./adt-VDU/public/adt-VDU20040825.110759.
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Aluminium die casting is a process used to transform molten aluminium material into automotive gearbox housings, wheels and electronic components, among many other uses. It is used because it is a very efficient method of achieving near net shape with the required mechanical properties. Life Cycle Assessment (LCA) is a technique used to determine the environmental impacts of a product or process. The Life Cycle Inventory (LCI) is the initial phase of an LCA and describes which emissions will occur and which raw materials are used during the life of a product or during a process. This study has improved the LCI technique by adding in manufacturing and other costs to the ISO standardised methods. Although this is not new, the novel application and allocation methods have been developed independently. The improved technique has then been applied to Aluminium High Pressure Die Casting. In applying the improved LCI to this process, the cost in monetary terms and environmental emissions have been determined for a particular component manufactured by this process. A model has been developed in association with an industry partner so this technique can be repeatedly applied and used in the prediction of costs and emissions. This has been tested with two different products. Following this, specialised LCA software modelling of the aluminium high pressure die casting process was conducted. The variations in the process have shown that each particular component will have different costs and emissions and it is not possible to generalise the process by modelling only one component. This study has concentrated on one process within die casting but the techniques developed can be used across any variations in the die casting process.
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Sivertsen, Halses Sebastian. "Die life prediction using High Pressure Die Casting simulations." Thesis, Tekniska Högskolan, Jönköping University, JTH, Material och tillverkning, 2020. http://urn.kb.se/resolve?urn=urn:nbn:se:hj:diva-50031.
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Global trends in automotive industry for weight reduction drives an interest for casting of structural aluminum parts. High pressure die casting (HPDC) is chosen for this purpose since it enables manufacturing of large series parts where complexity and repeatability is demanded. Aluminum alloys have hence been developed through the years to obtain suitable mechanical properties for high strength parts. These alloys have been investigated to predict the types of potential failure mechanisms during HPDC in order to determine die life through simulations. Die life prediction was performed through simulations in MAGMAsoft 5.4 with the help of a die life module, which is based on thermal stresses generated in the die material during casting cycles. Fatigue data at elevated temperature obtained from literature review of AISI H11 tool steel was complemented to the Wöhler curve in the software database. Comparison of two aluminum alloys showed that chemical composition had a major influence on die life. Chemical composition had a direct impact on solidification time and with longer solidification time, the thermal load on the die increased. Since the stress range on the die is temperature dependent, the ability of heat transfer over time proved to be critical for die life results. The most crucial process parameter to achieve a longer die life was constant cooling by tempering channels, due to their high potential to remove heat. Tempering channels and die spray also prevent the die from exceeding a critical temperature resulting in soldering formation. Mold erosion was consistently observed in the same location for all simulations.
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Watson, Douglas. "Microstructure and mechanical properties of ductile die-cast Al-Mg-Si-Mn alloys." Thesis, Brunel University, 2015. http://bura.brunel.ac.uk/handle/2438/12874.
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Aluminium alloys have been seen a dramatic increase in transport manufacturing in past two decades. This is primarily driven by the achievement of effective weight-savings, increased vehicle fuel efficiency and reduced CO2 emissions in transport. One of the significant progresses in most recent years has been in the application of aluminium-intensive car body structure, in which the manufacturing of thin wall castings with improved ductility is one of the critical issues. High pressure die casting (HPDC) is a fast and economical near-net shape manufacturing method to produce thin wall components. Therefore the application of HPDC process to make thin wall structural components for aluminium-intensive car body structure is one of the most challenges in recent development. However, the currently available die cast aluminium alloys are unable to fulfil this requirement because of the insufficient ductility, which is essential for joining castings with sheets and extruded parts. This has become critical in further development and extensive acceptance in car manufacturing industry. Generally, the mechanical properties of die castings are determined by alloy composition, defect levels and microstructure in the castings. In the present study, the significant achievement is the development of Al-Mg-Si-Mn alloy for HPDC process to provide improved ductility in die castings in order to satisfy the requirement of mechanical properties, in particular ductility for the application in automotive body structure. Starting from the thermodynamic analysis and CALPHAD (Computer Coupling of Phase Diagrams and Thermochemistry) modelling of Al-Mg-Si system for solidification and phase formation, the alloy composition was optimised using international standard tensile samples to review the effect of various alloying elements on the mechanical properties. Another achievement is the understanding of the solidification and microstructural evolution, the relationship between the microstructure and mechanical properties, and the strengthening mechanisms in the developed alloy. The solidification behaviour in the shot sleeve and in the die cavity was examined for the formation of the primary α-Al phase, eutectic Al-Mg2Si phases in the alloy. The morphology, size and size distribution of the primary α-Al phase were characterised under different solidification conditions. The growth morphology of the primary α-Al phase formed in the shot sleeve and in the die cavity was analysed using the Mullins-Sekerka instability theory and the growth rate of eutectic Al-Mg2Si phases during solidification was calculated using Jackson-Hunt theory. Still another achievement is the study of the effect of Mn and Fe on the morphology, size and distribution of various Fe-rich compounds in the Al-Mg-Si alloy produced by HPDC process. The assessment was associated with the mechanical properties of yield strength, ultimate tensile strength and elongation with different Fe and Mn contents. CALPHAD modelling of multi-component Al-Mg-Si-Mn-Fe and Al-Mg-Si-Fe systems was studied to find out the effect of Fe impurity in the Al-Mg-Si alloy. The precise accumulation of iron during HPDC using fully recycled materials was examined to predict the maximum cycles to produce castings with required mechanical properties. The strengthening mechanism and the relationship between the microstructure and mechanical properties are explored in the alloy made by secondary materials. Furthermore, the effect of nickel on the microstructure and mechanical properties of the die-cast Al-Mg-Si-Mn alloy was also studied in association with the formation of Ni-rich intermetallics during solidification in the die-cast Al-Mg-Si-Mn alloy containing different Ni contents. The final achievement is the understanding of the repeatability of die castings made by the new alloy with industrial scale components. The tensile properties of standard samples that were obtained directly from HPDC process and made by the machined die castings at different locations were further assessed for the reproducibility of casting components made by the Al-Mg-Si-Mn alloy. The distributions of yield strength, ultimate tensile strength and elongation of the tensile samples were analysed by the average values with standard deviations and by the Weibull statistical model with three parameters. The correlations between the mechanical properties and the microstructural features, porosity levels and fracture morphology were investigated for the different types of samples. It was found that three-parameter Weibull analysis was capable of analysing the reproducibility of die cast components and the scattering of tensile properties was mainly due to the presence of porosity and non-uniform microstructure in the die-castings.
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Pereira, M. F. V. T., M. Williams, and Preez W. B. Du. "Characterization of metal powder based rapid prototyping components with respect to aluminium high pressure die casting process conditions." Journal for New Generation Sciences, Vol 8, Issue 2: Central University of Technology, Free State, Bloemfontein, 2010. http://hdl.handle.net/11462/563.
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Published ArticleThis paper is based on tests performed on die component specimens manufactured by EOS-DMLS (direct metal laser sintering) and LENS (laser engineered net shape) RP (rapid prototyping) technology platforms, as well as manufactured specimens machined out of preferred standard hot work steel DIN 1.2344. These specimens resemble typical components used in metal high pressure die casting tool sets. The specimens were subjected to a programme of cyclic immersion in molten aluminium alloy and cooling in water-based die release medium. The heat checking and soldering phenomena were analyzed through periodic inspections, monitoring crack formation and evidence of surface washout. At the end of the thermal tests, mechanical strength and hardness tests were performed to assess toughness and core resistance variations in relation to the initial conditions. Finally metallographic investigations were performed through optical microscopy on all the specimens considered. The outcomes of this research will be presented and used by the CSIR for further development and application of the assessed EOS-DMLS and LENS rapid prototyping technologies in rapid die manufacturing techniques and die design principles, including time and economic feasibility criteria to be applied when considering rapid die manufacture.
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Pereira, Manuel Filipe Viana Teotonio. "ADDITIVE MANUFACTURING OF COMPONENTS FOR IN-DIE CAVITY USE, SUITABLE TO WITHSTAND ALUMINIUM HIGH PRESSURE DIE CASTING (HPDC) PROCESS CONDITIONS." Thesis, Bloemfontein: Central University of Technology, Free State, 2013. http://hdl.handle.net/11462/243.
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Thesis (M. Tech. (Engineering: Mechanical)) -- Central University of Technology, Free State, 2013This research examines the suitability of Additive Manufacturing (AM) for manufacturing dies used in aluminium high pressure die casting. The study was guided by the following objectives: • The reviews of applicable literature sources that outline technical and application aspects of AM in plastic injection moulds and the possibilities of applying it to high pressure casting die. • To introduce AM grown die components in die manufacture. Further, to develop a methodology that will allow industry to apply AM technology to die manufacture. • Revolutionise the way die manufacture is done. The potential for AM technologies is to deliver faster die manufacture turnaround time by requiring a drastically reduced amount of high level machining accuracy. It also reduces the number of complex mechanical material removal operations. Fewer critical steps required by suitable AM technology platforms able to grow fully dense metal components on die casting tools able to produce production runs. • Furthermore, promising competitive advantages are anticipated on savings to be attained on the casting processing side. AM technology allows incorporation of features in a die cavity not possible to machine with current machining approaches and technology. One such example is conformal cooling or heating of die cavities. This approach was successfully used in plastic injection mould cavities resulting in savings on both the part quality as well as the reduction on cycle time required to produce it (LaserCUSING®, 2007). AM technology has evolved to a point where as a medium for fast creation of an object, it has surpassed traditional manufacturing processes allowing for rapidly bridging the gap between ideas to part in hand. The suitability of the AM approach in accelerating the die manufacturing process sometime in the near future cannot be dismissed or ignored. The research showed that there is promise for application of the technology in the not too distant future. In the South African context, the current number and affordability of suitable AM platforms is one of the main stumbling blocks in effecting more widespread applied research aimed at introduction of the technology to die manufacture.
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Binney, Matthew N. "Porosity reduction in high pressure die casting through the use of squeeze pins /." [St. Lucia, Qld.], 2006. http://www.library.uq.edu.au/pdfserve.php?image=thesisabs/absthe19810.pdf.
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Míšek, Jakub. "Vliv odplynění na kvalitu odlitků vyrobených technologií vysokotlakého lití." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2017. http://www.nusl.cz/ntk/nusl-318844.
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This thesis examines the influence of the degassing process on hydrogen contend and on the quality of part casted by high pressure casting technologies. The type of defects occurring in the casting is analyzed based on macrostructure and microstructure observations. For the overall assessment is used the statistical observation of the evolution trend of scrapping during the experiment. The results show that shortening of the degassing time may affect the incidence of porosity defect.
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Knoll, Octavian [Verfasser], Karl [Mitwirkender] Schweizerhof, and O. S. [Akademischer Betreuer] Hoppenstad. "A Probabilistic Approach in Failure Modelling of Aluminium High Pressure Die-Castings / Octavian Knoll. Betreuer: Karl Schweizerhof ; O. S. Hoppenstad." Karlsruhe : KIT-Bibliothek, 2015. http://d-nb.info/1081213019/34.
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Klarner, Andrew Daniel. "Development of Mg-Al-Sn and Mg-Al-Sn-Si Alloys and Optimization of Super Vacuum Die Casting Process for Lightweight Applications." The Ohio State University, 2018. http://rave.ohiolink.edu/etdc/view?acc_num=osu1515083355012541.
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Jankes, Erik. "Využití řízeného naplyňování slitin Al-Si při tlakovém lití." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2015. http://www.nusl.cz/ntk/nusl-231052.
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This master thesis will cover the possibility of using directed gassing of Al-Si alloys in a high pressure die casting foundry. As a control gas, rotary degasser with gaseous 20 % H2 in N2 as a medium was used. Castings were casted via high pressure die casting machine. The aim of this research is to compare internal defect such as porosity or shrinkage of a casts made from degassed and control gassed melt.
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Afsaridis, Kimon. "Investigation of residual stresses generation in aluminum flywheel." Thesis, Jönköping University, Jönköping University, JTH. Research area Product Development, 2009. http://urn.kb.se/resolve?urn=urn:nbn:se:hj:diva-9255.
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Quality of the castings is affected by several factors which the designer should take into consideration during the product development process. Although residual stress is one of those, it is often not considered in practical computations. Hence residual stresses are one of the forgotten areas in designing of machine parts. This master thesis is focused on the investigation of residual stresses in a high pressure die casted component, with the aim of extending its service life, by taking results from the study as a feedback.
The investigation of residual stresses was done on a variety of specimens, cast aluminum flywheel, provided by Husqvarna AB. This flywheel is a component in a product of the same company.In evaluating the residual stresses in the part, two tools-simulation and physical measurement were used. Moreover, comparison with these two methods is also done at an area of interest on the flywheel. The simulation was carried out by using MAGMAhpdc-a module for high pressure die casting process, from the commercial software package MAGMAsoft; while for the physical measurements, the hole drilling method was used, a method believed to be less accurate at low stresses areas.
The findings obtained from this study show that the results from both procedures are close, with small deviations observed, which reveals the reliability of the hole drilling method even when the stress levels are low. It is also found that the compressive residual stresses dominate in the component-a preferred phenomenon with regards to residual stress.
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Chintalapati, Pavan. "Solidification under pressure of aluminum castings." Birmingham, Ala. : University of Alabama at Birmingham, 2009. https://www.mhsl.uab.edu/dt/2010r/chintalapati.pdf.
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Thesis (Ph. D)--University of Alabama at Birmingham, 2009.Title from PDF t.p. (viewed June 30, 2010). Additional advisors: Viola L. Acoff, Krishan K. Chawla, Raymond J. Donahue, Gregg M. Janowski, Harry E. Littleton (ad hoc). Includes bibliographical references (p. 143-138).
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Hamasaiid, Anwar. "Transferts thermiques interfaciaux en fonderie en moules métalliques d'alliages légers." Toulouse 3, 2007. http://www.theses.fr/2007TOU30249.
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L'objectif de ce projet est d'étudier les transferts thermiques interfaciaux pendant la solidification des alliages légers dans les procédés de fonderie par gravité et sous pression. Pour cela, nous avons développé des méthodes expérimentales et des capteurs appropriés permettant d'effectuer les mesures de température dans le moule et en surface de la pièce pendant le remplissage et la solidification. Nous avons également enregistré les paramètres procédés sur une installation de fonderie sous pression particulièrement bien instrumentée. Pour la mesure de température de surface de la pièce coulée, nous avons adapté une technique pyrométrique utilisant un pyromètre et une fibre optique auxquels nous avons ajouté un crystal de saphir transparent dans la gamme de longueur d'onde du pyromètre. Ainsi, nous avons effectué plusieurs centaines de cycles pendant lesquels trois alliages ASG03, AS9U3 et AZ91D ont été coulés par ces deux procédés. Les mesures de température ont été exploitées par une méthode inverse pour évaluer le coefficient d'échange thermique et la densité de flux de chaleur à l'interface pièce/moule pour chaque cycle effectué. Les résultats obtenus ont été comparés entre les diverses conditions de coulée et avec les microstructures des pièces produites. Nous avons proposé deux modèles analytiques pour la Résistance Thermique de Contact (RTC) à l'interface liquide/solide pour les deux conditions de contact rencontrées dans les deux procédés étudiés. .The present investigation is about the interfacial heat transfer during the solidification of light alloys in Gravity (GDC) and High Pressure (HPDC) Die Casting processes. The study consists of three principle fields, experimental, analytical and modelling. The Experimental activity involves measuring the temperature around the casting-die interface, in the mould and at the surface of the castings and other process parameters during die filling and solidification. For this purpose, suitable experimental methods and sensors have been developed. Particularly a pyrometric measurement method has been adapted to measure the casting surface temperature during its solidification. Hundredths of trials were performed using Al-7Si-0. 3Mg, A-9Si-3Cu and AZ91 D alloys during the two investigated processes. From the temperature measurements, interfacial heat transfer coefficient and heat flux density have been evaluated using an inverse method. The obtained results have been analysed with regards to the various process parameters and to the microstructure of the castings. .
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Vicario, Gomez Iban. "Influence des nano-particules d’alumine (Al2O3) et de di-borure de titane (TiB2) sur la microstructure et les propriétés de l’alliage Al-Si9-Cu3-Fe1 pour des applications de fonderie à haute pression." Thesis, Bordeaux 1, 2011. http://www.theses.fr/2011BOR14420/document.
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Ce travail est dédié á l´étude de l´influence de nano-particules de alumina (Al2O3) et de di-borure de titane (TiB2) sur la solidification, la microstructure et les propriétés thermiques et mécaniques de l´alliage d´aluminium renforcés, Al-Si9Cu3Fe1. Les matériaux ont été obtenus par un procédé de fonderie à haute pression en coulant les alliages dans les mêmes conditions que les alliages non renforcés correspondants.On a constaté que les particules de Al2O3 et de TiB2 ont une influence directe sur les caractéristiques de l´alliage telles que la microstructure, la précipitation des phases pendant la solidification et les propriétés mécaniques et électriques. On a ainsi montré que les particules de Al2O3 et de TiB2 peuvent être utilisées pour ajuster les caractéristiques des alliages et obtenir des propriétés spécifiques pour des applications dans les secteurs de matériaux légersThe work has been focused on the study of the influence of TiB2 and Al2O3 nano-particles (up to 1 wt. %) on the properties and physical features of an aluminium casting alloy, Al-Si9Cu3Fe1.Samples have been obtained through the High Pressure Die Casting (HPDC) process and compared with unreinforced samples obtained at the same conditions. It has been observed that the Al2O3 and TiB2 particles have a direct influence on several features of the alloy such as the microstructure and precipitating phases as well as in the improvement of the soundness and mechanical and electrical properties. Al2O3 and TiB2 particles can be used to tailor the properties of the alloy and to match the specifications of light weight applications
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Tavakoli, Shahab. "Modélisation du cycle thermique des moules de fonderie sous pression." Thesis, Paris 10, 2014. http://www.theses.fr/2014PA100095.
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La réduction de la masse des véhicules, notamment des Groupes Motopropulseurs contribue à la réduction des émissions polluantes. Aujourd’hui afin d’aboutir à cet objectif, la conception de pièces automobiles (Carter Mécanisme, Carter Cylindre) en matériau allégé tel que l’aluminium et ses alliages est en plein essor. Pour la production de grande série, ces alliages sont mis en œuvre par le procédé de fonderie ‘’Aluminium sous pression’’.Ce procédé utilise des moules métalliques. La maîtrise du comportement thermique du moule : chauffage, refroidissement interne (par circuit) et externe, est un point clef pour la qualité et la cadence de production.Dans ce mémoire, le processus industriel est détaillé depuis la fermeture du moule et l’injection du métal liquide jusqu’à l’ouverture du moule et l’extraction de la pièce (carter mécanisme RENAULT). Ensuite, le design détaillé du moule, les différentes générations de circuit de refroidissement et les paramètres de chaque étape de la fabrication utilisés compte tenu du système de refroidissement actuel sont présentés. Le circuit de refroidissement du moule est aujourd’hui positionné dans le moule de façon empirique. Le but ultime de cette thèse est de donner les éléments clés de la conception du circuit de refroidissement d’un point vue thermique. Pour cela, une modélisation complète du phénomène a été réalisée et validée par 8 thermocouples et la position du system de refroidissement a été définie a partir des équations thermiques. Le cycle thermique du moule a été donc optimisé et nous a permis d’abaisser et d’homogénéiser les champs de température à la surface du moule pendant la production en vue d’une augmentation de la productivité, la santé des pièces et la durée de vie du mouleReducing the weight of vehicles, specially the powertrain Group, contributes to the reduction of the emissions. Today, in order to achieve this objective, the automobile parts conception (Housing gear box, Cylinder block) in lightweight materials such as aluminum and its alloys is increasing. For the mass production, aluminum alloys are formed by a foundry process called ‘’High Pressure Die Casting’’.This process uses the metal molds. Control the thermal behavior of the mold : Heating, intern cooling (by circuit) and extern cooling, is a key point to ensure castings quality and rate of production.In this thesis, the industrial process has been detailed since the mold closing and aluminum melting injection in the die, to the mold opening time and the part (Gearbox RENAULT) ejection. Then, the mold design details, different generation of the cooling systems and the parameters of each step of the manufacturing process taking into account the actual cooling system are presented. The actual cooling systems in the dies are positioned today in empirical way. The ultimate goal of this thesis is to provide the key elements for the cooling system conception from the thermal behavior point of view. For this one, a complete modeling of the phenomena has been realized and validated by 8 thermocouples and the cooling system position has been defined from the thermal equations. The thermal cycle of the die has been optimized and allowed us to reduce and homogenize the temperature fields on the die surface during the production. The rate of production, the castings quality and the lifetime of the die have been consequently increased
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Butler, Simon Andrew. "The development of a reliable high strength aluminium casting alloy." Thesis, University of Birmingham, 2000. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.570853.
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An investigation was carried out into the variability of tensile properties of A201 aluminium alloy investment castings. Fracture surfaces and microstructures of tensile specimens were examined by scanning electron and light microscopy. Chemical analysis of phases was carried out using energy dispersive x-ray analysis. Casting composition variations were measured using spark emission spectroscopy. The main factors that contributed to the variation of properties were incipient grain boundary melting during heat treatment, the macro segregation of chemical alloying elements and interdendritic porosity that had not sealed during the hot isostatic pressing (HIPping) process. Simple step plate castings were produced to investigate the effect of changes in section thickness on the local segregation of alloying elements. The compositional variations occur due to the flow of solute rich liquid through the dendrite interstices in the mushy zone. An investigation was carried out into the effect of titanium diboride particles on the formation of macro segregation and interdendritic porosity. It was found that by increasing the concentration of titanium diboride particles above 2.7 +/- 0.2 % the tendency for macro segregation was reduced to negligible levels. The formation of surface connected pores, as revealed by dye penetrant examination, was also reduced when this. concentration was exceeded. The change in the solidification behaviour is due to a lack of coherent dendrite formation in the mushy zone. This results in solidification contraction being compensated for by mass feeding rather than interdendritic fluid flow of liquid through the dendrite interstices. An additional effect of the presence of the particles was to prevent the formation of a low melting point'phase containing copper, magnesium and silver. This reduced the susceptibility of the alloy to grain boundary incipient melting during solution heat treatment. In the light of the findings of the experimental work the concept of casting reliability is discussed. The importance of preventing the variability of tensile properties by robust alloy design is highlighted. The future design and development of reliable components with regard to process specification and property prediction is discussed.
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Long, A. D. "Extending life of High Pressure Die Casting Dies." Thesis, Queen's University Belfast, 2010. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.527834.
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Sadeghi, Mohammad. "Optimization product parts in high pressure die casting process." Licentiate thesis, Mälardalens högskola, Framtidens energi, 2015. http://urn.kb.se/resolve?urn=urn:nbn:se:mdh:diva-27733.
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This thesis describes optimization of die temperature in high pressure die-casting (HPDC) of A380 alloy by experimental observation and numerical simulation with the use of statistical tools. The goal of this research is to determine the optimum die temperature to minimize incidence of these defects and thus maximize production of parts without defects. In HPDC, molten metal is injected into the die at high speed (40-60 m/s for aluminum alloys). Die temperature plays an important role on the rate of rejected parts. Therefore, flow patterns of molten metal in HPDC of an automotive component with very complex geometry (the ladder frame from the EF7 motor) were examined to determine the optimal die temperature. Defects in the production process fall into three categories, including surface, internal and dimensional defects. Samples produced in the experiments were classified according to any present defects. Another important parameter that influences casting defects is the cooling rate. Die temperatures were measured at the initial step and final filling positions. Experiments were performed with die temperatures ranging from 150 °C to 250 °C. The results show that the melt temperature difference in the die between the initial step and the final filling position was between 20 and 25 °C. Statistical tools such as regressions, relationships, max, min, correlations, ANOVA, T-test, Principal Component Analysis (PCA) and descriptive statistics were used to facilitate interpretation of data from the die-cast experiments. Perform some case studies in order to study the process behavior, take a better knowledge of effective parameters, and measure the required parameters. The collected data are utilized to: Set the model Validate/ verify the model ProCast software was used to simulate the fluid flow and solidification step, and the results were verified by experimental measurements. The optimal die temperature for this alloy was found to be above 200 oC. Statistical analysis of the experimental results found that defects were minimized and confirmed parts were maximized in HPDC of the ladder frame within a die temperature range of 210° C to 215° C.
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Elfakharany, Essameldin F. "Qualitative Reasoning for filling pattern in high-pressure die-casting and gravity-driven casting /." The Ohio State University, 1999. http://rave.ohiolink.edu/etdc/view?acc_num=osu1488192447430967.
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Graziani, Alessandro. "Chemical composition modification of casting aluminium alloys for engine applications." Master's thesis, Alma Mater Studiorum - Università di Bologna, 2016. http://amslaurea.unibo.it/10018/.
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The research activities were focused on evaluating the effect of Mo addition to mechanical properties and microstructure of A354 aluminium casting alloy. Samples, with increasing amount of Mo, were produced and heat treated. After heat treatment and exposition to high temperatures samples underwent microstructural and chemical analyses, hardness and tensile tests. The collected data led to the optimization of both casting parameters, for obtaining a homogeneous Mo distribution in the alloy, and heat treatment parameters, allowing the formation of Mo based strengthening precipitates stable at high temperature.
Microstructural and chemical analyses highlighted how Mo addition in percentage superior to 0.1% wt. can modify the silicon eutectic morphology and hinder the formation of iron based β intermetallics. High temperature exposure curves, instead, showed that after long exposition hardness is slightly influenced by heat treatment while the effect of Mo addition superior to 0,3% is negligible. Tensile tests confirmed that the addition of 0.3%wt Mo induces an increase of about 10% of ultimate tensile strength after high temperature exposition (250°C for 100h) while heat
treatments have slight influence on mechanical behaviour.
These results could be exploited for developing innovative heat treatment sequence able to reduce residual stresses in castings produced with A354 modified with Mo.
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Yan, Feng. "Development of high strength Al-Mg2Si-Mg based alloy for high pressure diecasting process." Thesis, Brunel University, 2014. http://bura.brunel.ac.uk/handle/2438/13883.
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Aluminium alloys are the most promising lightweight materials used in the automotive industry to achieve weight reduction for improving fuel efficiency and reducing CO2 emissions. High pressure diecasting (HPDC) is a fast and economical near-net shape manufacturing method to produce engineering components. About 80% of cast aluminium alloys are currently manufactured by HPDC. The increased demands of manufacturing structural components by HPDC process require high strength Al-alloys for the automotive industry. However, the currently available die cast Al-alloys are unable to fulfil this requirement. Al-Mg2Si alloy is known as an alloy capable of providing superior high strength by Mg2Si particles. However, Al-Mg2Si alloy is not applicable in the HPDC process because of the severe die soldering problem. This has limited its applications throughout industries. Moreover, the existing studies on the Al-Mg2Si alloy are mainly focused on the hyper-eutectic alloys and limited information is available for hypo-eutectic alloys. Generally, the mechanical properties of Al-alloys are determined by the alloy composition, the defect levels in the components, the microstructure which is mainly controlled by the casting process and heat treatment process. Due to the high cooling rate provided by the die block in the HPDC process, the refined microstructure in the die cast Al-Mg2Si alloys can be obtained to improve the mechanical properties. Therefore, the development of high strength Al-Mg2Si based alloys for the HPDC process is significant for manufacturing quality automotive components. The present study mainly focuses on the alloy development for the HPDC process. In order to make die castable Al-Mg2Si based alloys, the effect of excess Mg has been investigated to modify the hypo-eutectic Al-Mg2Si system for improving the mechanical properties. The effect of excess Mg on the solidification and microstructural evolution, and the mechanical properties of Al-Mg2Si alloys, has also been investigated by the combination of thermodynamic calculation and the experimental validation. The excess Mg in the hypo-eutectic Al-Mg2Si alloys has been found to be able to shift the eutectic composition to a lower Mg2Si content, which means that the hypo-eutectic composition of Al-Mg2Si alloy can be at eutectic or hyper-eutectic compositions after adding different levels of excess Mg. The experimental trials have also found that Al-8Mg2Si-6Mg alloy provides the best combination of strength and ductility in the as-cast castings made by the HPDC process. This can be further enhanced by adding 0.6wt.% Mn, which exhibits yield strength of 189MPa, UTS of 350MPa, and elongation of 6.5%. Investigations have also revealed that the Al-8Mg2Si-6Mg alloy exhibits a relatively high tolerance to the Fe impurity because of the insignificant reduction of ductility of the alloy. The elongation is still at a level of 5% when Fe is at 1.6wt.% in the alloy. Furthermore, Cu and Zn can further enhance the mechanical properties of the Al-8Mg2Si-6Mg-0.6Mn alloy. Cu contents between 0.31wt.% and 0.92wt.% in the Al-8Mg2Si-6Mg-0.6Mn alloy can increase the yield strength from 193MPa to 207MPa, but decrease the UTS from 343MPa to 311MPa, and the elongation from 4.8% to 3.8% under as-cast condition. This can be attributed to the formation of hot tearing defects in castings. Therefore, the Cu content in the alloy should be limited to a low level. On the other hand, zinc can be controlled to a level of 4.3wt.%, which will dramatically increase the tensile strength of the alloy. More importantly, Zn can significantly increase the mechanical properties of the alloy after a quick T6 heat treatment under a condition of solution at 490oC for 15 mins and ageing at 180oC for 90 mins, at which the yield strength is 345MPa, UTS is 425MPa, and elongation is 3.2 %. In the present study, the solidification and microstructural evolution, the relationship between the microstructure and mechanical properties, and the strengthening mechanisms in the developed alloy are discussed on the basis of the experimental results. A two stage solidification has been recognised to be responsible for the microstructure formation in the HPDC process. The primary α-Al phase is formed as prior phase for the hypo-eutectic alloy and the primary Mg2Si phase is formed as prior phase for the hyper-eutectic alloy. The solute elements including Mg, Mn, Fe, Cu, and Zn can enhance the solution strengthening and/or the precipitation strengthening in the alloys, but alter the solidification ranges, which will affect the formation of defects in the castings. In the quick T6 heat treatment, the AlMgZn phase is dissolved into the Al phase during solution treatment and precipitated during ageing treatment. The quick heat treatment is also found to be able to spheroidise the Mg2Si phase. Only η′ MgZn phase is precipitated during aging in Zn containing alloys. The alloy with 4.3wt.% Zn provides the best combination of the mechanical properties because of the high density of MgZn precipitates in the α-Al phase.
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Carbin, R. "Factors affecting the production of aluminium alloy automotive wheels by the low pressure die casting process." Thesis, Swansea University, 1994. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.636205.
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It was found that the addition of strontium modifier to the melt significantly altered both the euctectic silicon particle size and morphology and the porosity size and distribution developed on solidification. The eutectic silicon phase was transformed from one of large, elongated interconnected flakes to that to much finer more rounded particles. Porosity size and distribution was found on modification to change from that of many fine pores distributed across the whole sample cross section to that of very much fewer, widely dispersed but larger pores separated by sound material. Addition of titanium based grain refining master alloy to the melt was found to produce a different effect on porosity distribution depending on what form of addition was made. A binary Al-6Ti addition was found to cause a sharp increase in the number of pores developed, when compared to the modified only material. A ternary Al-5Ti-1B addition, on the other hand, was found to produce only a modest increase in the number of pores developed. It was also found that for the same melt hydrogen content, TiAl grain refined melts produced samples that were systematically more porous, as assessed by density, when compared to TiBAl grain refined samples. Stirring of the melt immediately prior to the obtaining of the test castings was found to cause an increase in the number of pores in TiBAl refined melts, and to cause a partial loss of modification, while stirring had less effect for either TiAl refined or modified only melts. With regard to rim cooling method, it was found that the technique producing the harshest cooling resulted in the production of the finest microstructure, not only in the rim region, but across the whole wheel section. It was found that dendrite arm spacing was finer, and the occurrence of damaging acicular intermetallic particles was much reduced.
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Spataro, Mark Paul. "Comparison of mechanical performance between magnesium alloy sand castings and high pressure die castings /." [St. Lucia, Qld.], 2004. http://www.library.uq.edu.au/pdfserve.php?image=thesisabs/absthe18378.pdf.
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Clinch, Michael. "The thermomechanical processing of aluminium alloys for high pressure gas cylinders." Thesis, University of Nottingham, 2000. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.326551.
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Tang, Caixian. "Soldering in magnesium high pressure die casting and its preservation by surface engineering." Swinburne Research Bank, 2007. http://hdl.handle.net/1959.3/22747.
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Thesis (PhD) - Swinburne University of Technology, Industrial Research Institute Swinburne - 2007.[A thesis submitted] for the degree of Doctor of Philosophy, Industrial Research Institute, Swinburne University of Technology - 2007. Typescript. Includes bibliographical references (p. 154-167).
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Fraser, Darren T. "Soldering in high pressure die casting and its prevention by lubricant and oxide layers /." [St. Lucia, Qld.], 2000. http://adt.library.uq.edu.au/public/adt-QU20010830.163828/.
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Yang, Xinliang. "Particle dispersion in aluminium and magnesium alloys." Thesis, Brunel University, 2016. http://bura.brunel.ac.uk/handle/2438/14437.
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High shear mixing offers a promising solution for particle dispersion in a liquid with intensive turbulence and high shear rate, and has been widely used in the chemical, food and pharmaceutical industries. However, a practical high shear mixing process has not yet been adapted to solve the particle agglomeration in metallurgy due to the high service temperature and reactive environment of liquid metal. In this study, the effect of high shear mixing using the newly designed rotor-stator high shear device have been investigated with both Al and Mg matrix composites reinforced with SiC particles through casting. The microstructural observation of high shear treated Al and Mg composites show improved particle distribution uniformity in the as-cast state. Increased mechanical properties and reduced volume fraction of porosity are also obtained in the composite samples processed with high shear. With the melt conditioning procedure developed for twin roll casting process, two distinct solutions has been provided for thin gauge Mg strip casting with advanced microstructure and defect control. The melt conditioning treatment activates the MgO as heterogeneous nuclei of α-Mg through dispersion from continuous films to discrete particles. Thus enhanced heterogeneous nucleation in the twin roll casting process not only refines the α-Mg grain size but also eliminates the centre line segregation through equiaxed grain growth and localized solute distribution. The grain refinement of the α-Mg through SiC addition has also been studied through EBSD and crystallographic approaches. Two reproducible and distinct crystallographic orientation relationships between α-SiC (6H) and α-Mg have been determined: [1010]SiC//[2113]Mg, (0006)SiC//(1011)Mg, (1216)SiC//(2202)Mg and [0110]SiC//[1100]Mg, (0006)SiC// (0002)Mg, (2110)SiC//(1120)Mg.
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Gulizia, Stefan. "Soldering in high pressure die casting (HPDC) performance evaluation and characterisation of physical vapour deposition (PVD) coatings /." Swinburne Research Bank, 2008. http://hdl.handle.net/1959.3/39640.
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Thesis (MEng) - School of Engineering and Science, Swinburne University of Technology, 2008.Thesis submitted for the degree of Master of Engineering, School of Engineering and Science, Swinburne University of Technology, 2008. Typescript. Includes bibliographical references (p. 98-101).
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Newell, Matthew David. "Aspects of a novel casting process for the production of nickel-based superalloy high pressure turbine blades." Thesis, University of Birmingham, 2009. http://etheses.bham.ac.uk//id/eprint/525/.
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A novel process in which individual turbine blades are produced by the high rate solidification method has been developed. The technology, with an optimised radiation baffle, gave a thermal gradient of 11.64 x 10\( 3\) K.m\( {-1}\), whilst maintaining a flat solidification front, calculated using a specially created and validated process model. The corresponding primary dendrite arm spacing was reduced to 165 x 10\( {-6}\) m and the calculated freckle potential was below the critical threshold limit identified by Beckermann et al. (2000), even in highly freckle prone alloys. Low angle grain boundaries formed when misorientation accumulates in growing dendrite envelopes which subsequently converge were studied experimentally. While extensive dendrite branching or steady state growth was found to lead to an average primary dendrite misorientation of 2.3 ° that was random in nature, enhanced growth kinetics accompanying non steady state growth, found in platforms, produced a monotonic increase in accumulated misorientation of up to 10 °. It was concluded that the latter is due to mechanical moments arising from extensive growth of unsupported tertiary dendrite branches growing laterally across the platform normal to the direction of gravity. The degree of misorientation is therefore dependent on local geometry and mushy zone shape.
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Schaub, Henning. "Comparison of different aluminium casting processes from an environmental perspective : Case study on plaster mould castings produced in Mid Sweden." Thesis, Mittuniversitetet, Avdelningen för ekoteknik och hållbart byggande, 2018. http://urn.kb.se/resolve?urn=urn:nbn:se:miun:diva-35659.
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While Aluminium has lots of unique properties and is seen as a material of the future, its production and manufacturing has significant environmental impacts. For complex and dimensional shapes casting remains the main manufacturing method and in this study the environmental pressure of different casting techniques is compared. A screening LCA is conducted to determine the environmental impacts of plaster mould castings in a case study at the Ventana Hackås AB foundry in Mid Sweden. The findings are compared to models of sand, pressure die and lost wax castings, based on literature datasets. The most relevant factors for the environmental performance are identified as the production of the aluminium alloy and the amount and source of energy. For plaster mould castings additionally the plaster consumption is significant, while lost wax castings are dominated by the mould production and general processes. Under similar circumstances a relatively similar performance was found for all casting techniques except the lost wax process, which is at least 3 times more emission intensive. Of the remaining techniques pressure die castings performed the best and plaster mould castings the worst, but different sources of uncertainties have been identified in this comparison. In addition a carbon footprint interface is created based on these findings, to enable specific comparisons of different casting method setups. Customizable variables allow the adaptation of three scenarios to real world conditions. As the main influencing factors the aluminium alloy, source of electricity and casting technique have been identified.2018-10-10
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Watson, Robert. "New numerical techniques to quantify and predict the effect of entrainment defects, applied to high pressure die casting." Thesis, University of Birmingham, 2016. http://etheses.bham.ac.uk//id/eprint/7153/.
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High Pressure Die Casting (HPDC) is an attractive option for automotive manufacturers, as it has a number of advantages over wrought process routes. An improved understanding of the defects which may result from the process could allow castings to deliver lighter vehicle structures. A novel algorithm was developed to predict the formation of entrainment defects, which may limit the strength of castings. This model was integrated into FLOW-3D, a fluid dynamics solver. Theoretical advances were made, which offer a means of extrapolating a spatial distribution of damage to location specific statistical distributions, an improved way of characterising the contribution of each defect type to strength, and a means of correlating parameters for statistical distributions, allowing the variation in strength may be predicted at arbitrary locations within a casting. Casting and numerical experiments were performed, to evaluate these algorithms and underlying fluid flow solution, and to test the influence of entrainment defects on the strength of HPDC parts. Defects formed by air entrainment were found to significantly limit the strength of the studied castings. The methods and techniques explored in this work showed promise, but further advances would be needed, before ab intio strength prediction for HPDC parts can be realised.
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Law, Madeleine. "Investigations on the Formation of Defect Bands in Semi-Solid High Pressure Die Cast Aluminium-Silicon Alloys." Licentiate thesis, KTH, Materialvetenskap, 2020. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-272086.
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High-pressure die casting of semi-solid aluminium-silicon alloys is used in the automotive industry to manufacture components, like housings, brackets, and bars. It is commonly known that during high-pressure die casting, defect bands may be created that follow the contour of the component surface. These bands consist mainly of a eutectic phase. This phenomenon is also observed in semi-solid metal slurry high-pressure die casting. These bands could lead to premature failure of the component in service. The origin of these bands is not fully understood and so this research focuses on investigating these bands and their origins further. A series of casting trials were conducted with varying plunger velocity. Subsequent investigation using optical and scanning electron microscopy showed that a change of the plunger velocity alters the number of bands present in the samples. Energy dispersive X-ray spectroscopy revealed that a measurable difference in aluminium quantity across the band was noticed and it was postulated that aluminium migrates towards the component centre. Therefore, different mechanisms responsible for particle migrations found in literature were investigated and assessed quantitatively using experimental data and information from published literature. It was found that the Saffman lift force and the Mukai-Lin-Laplace effect were the mechanisms that were most likely to cause such a migration of aluminium. Further experimental investigation is recommended to identify which of the two mechanisms is ultimately responsible for the migration and to optimise the high-pressure die casting procedure to minimise defect band formation.Produktion av högtrycksgjutning av halvfasta aluminium-kisellegeringar används i fordonsindustrin för att tillverka komponenter, som exempel till kåpor, konsoler och stag. Det är allmänt känt att defektband kan formas under högtrycksgjutning som följer konturen av komponentytan. Dessa band består huvudsakligen av eutektisk fas. Detta fenomen har också observerats vid högtrycksgjutning produktion av halvfast slurry. Potentiellt kan dessa band leda till en försämring av komponentens mekaniska egenskaper och resultera i ett förtida brott. Ursprunget av dessa band är inte helt kartlagda och det är därför viktigt att fokusera ytterligare på denna forskning och att undersöka dessa band och deras ursprung. En serie med gjutningsförsök genomfördes med varierande kolvhastighet. Efterföljande undersökning med optisk- och svepelektronmikroskopi visade att en förändring av kolvhastigheten förändrar antalet band som finns i proverna. Energidispersiv röntgenspektroskopi avslöjade en mätbar skillnad i aluminiumkvantitet över bandet, och det antogs att aluminium migrerar mot centrum av komponenten. Därför undersöktes och utvärderades olika mekanismer som ansvarar för partikelmigrationer som finns att finna i litteratur med hjälp av experimentella data och information från publicerad litteratur. Det visade sig att Saffman lyftkraft och Mukai-Lin-Laplace effekten var de mekanismer som mest troligen orsakade migration av aluminium. Ytterligare experimentella försök rekommenderas för att identifiera vilken av dessa två mekanismerna som i slutändan är ansvarig för migrationen. Detta för att optimera gjutningsprocessen och därmed minimera uppkomsten av defektband.
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Okcu, Isik Yilmaz. "Effect Of Process Parameters On Mechanical Properties Of High Pressure Die Cast Magnesium Az91 Components." Master's thesis, METU, 2011. http://etd.lib.metu.edu.tr/upload/12613896/index.pdf.
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Before beginning the experimental work of this study, a magnesium high pressure die casting facility is set up to manufacture magnesium cast parts for defence industry. In this thesis two components are cold chamber high pressure die casted using magnesium alloy AZ91 as raw material, and one component was manufactured using both aluminium alloy A.413, and magnesium alloy AZ91.
Mechanical properties of high pressure die casting parts depend on various parameters such as, thickness of the cast part, position of the cast part in the cavity, molten metal temperature, die temperature, piston speeds, and injection pressure. The aim of this study is to investigate the effects of section thickness of the cast part, position of the cast part in the die cavity, piston speeds, and molten metal temperature on mechanical properties of magnesium die cast parts. Tensile properties of products from Al A.413 and Mg AZ91 alloys are also compared.
Casting analysis software is used to simulate filling and temperature evolution of three different casting components. Piston speeds are first calculated from equations in the literature and then verified by using the software. Specimens for microstructural investigation, and mechanical tests are machined directly from the mass produced parts. Optical microscopy, and scanning electron microscopy investigations are carried out for grain size and porosity determination. Tensile tests are conducted for yield strength, ultimate tensile strength, and % elongation values. The results of casting analysis software simulations, grains size investigations, porosity investigations, and tensile tests are correlated to each other.
Optimum piston speeds, optimum molten metal temperatures are observed, effect of grain size and porosity concentrations on the effect of mechanical properties are compared. Weight of cast parts produced from Mg AZ91 are 35 % lower than that of Al A.413 parts. However, ultimate tensile strength of the cast parts produced from Mg AZ91 are found to be similar to the aluminium parts.
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Pereira, M. F. V. T., M. Williams, and R. Bruwer. "Rapid die manufacturing using direct laser metal deposition." Journal for New Generation Sciences, Vol 7, Issue 3: Central University of Technology, Free State, Bloemfontein, 2009. http://hdl.handle.net/11462/542.
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Published ArticleGlobal issues such as energy and climate changes have impacted on both the automotive and aerospace industries, forcing them to adopt measures to produce products that consume fewer combustibles and emit less carbon dioxide. Making vehicles lighter is one of the logical ways of reducing fuel consumption. The need for light components, able to fulfil technical and quality specifications, led to market growth for tooling that is able to mass produce parts using manufacturing processes such as high pressure die casting. Competitive pressures to reduce the lead time required for tooling-up has also increased dramatically. For this reason research into various methods, techniques and approaches to tool manufacture is being undertaken globally. This paper highlights the work undertaken at the CSIR on the issue of rapid die manufacturing through the application and evaluation of a rapid prototyping technique and coating technologies applied to die components of a high pressure casting die for the production of aluminium components. Criteria for determining suitability were developed against which the technique was evaluated that included time, cost and life-expectancy. Results of accelerated testing procedures to evaluate the die material produced by the rapid prototyping technique and surface coatings and treatments of die materials for their resistance to washout, erosion, heat checking and corrosion in a high pressure die casting environment, are presented. The outcomes of this research will be used for further development and application of specific techniques, design principles and criteria for this approach.
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Štipl, Pavel. "Technologie lití vysokotlakých odlitků a vlivy působící na jejich kvalitu." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2014. http://www.nusl.cz/ntk/nusl-231432.
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This diploma thesis deals with the technology of high pressure die casting and especially influences having effect on their final quality. The aim of this thesis is to design the measures to convert casting of the cylinder for chainsaw into the serial production. The thesis contains a description of the production of castings by technology of high pressure die casting, theoretical analysis of the factors with effects on their final quality and practical description of the conversion casting of cylinder for chainsaw into the serial production. The problem of converting to serial production has been solved by several samplings and final test series. Part of each sampling is analysis of defects and design of measures leading to elimination or at least minimization of such defects. On the basis of the production process has been successfully optimized and casting of the cylinder for chainsaw was successfully converted into the serial production. The results of this work also allowed for a smooth conversion into the serial production of another type of cylinder, manufactured by company MOTOR JIKOV.
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Dočekal, Václav. "Vady tlakově litých odlitků ze slitin hliníku." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2019. http://www.nusl.cz/ntk/nusl-401515.
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This thesis is focused on defects occurring in products made by high pressure die casting of aluminum alloys. The theoretical part includes introduction to high pressure die casting technology and description of individual defects, causes and corrective procurations. The practical part focuses on the determination of the defect on the pre-selected casting, which is cast in the foundry ALW INDUSTRY, s.r.o. Based on the identification of the defect, there is a corrective procuration to reduce its occurrence.
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Svoboda, Rostislav. "Tlakově lité odlitky z Mg slitin - trendy vývoje." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2008. http://www.nusl.cz/ntk/nusl-228049.
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The aim of this thesis is to determine influence of porosity and shape-factor over mechanical properties, performed on cast samples from Aalen foundry (Germany), that were high pressure die casted from AZ91 D Alloy. Evaluation of these quantities was done using computer software Olympus Five. Measured values were subjected to statistical analysis in order to eliminate gross errors and determine linear dependence between mechanical properties and porosity eventually voids shape factor.
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Outmani, Imane. "Caractérisation des variabilités Matériaux/ Process pour une convergence produit de fonderie par approche prédictive." Thesis, Paris, ENSAM, 2017. http://www.theses.fr/2017ENAM0007/document.
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Les alliages Al-Si sont largement utilisés dans l’industrie automobile en fonderie sous pression, en particulier pour la fabrication des blocs moteurs, en raison de leurs bon rapport résistance/ poids et leurs excellentes propriétés mécaniques. Du fait de l’internationalisation de la production, la composition chimique de ces alliages et les paramètres du procédé HPDC peuvent varier d’un pays à l’autre, ils peuvent même varier d’un site de fabrication à l’autre dans le même pays. Or, les conceptions des pièces automobiles sont aujourd’hui de type déterministe et elles sont réalisées sur la base des matériaux et procédés européens, ce qui peut affecter les propriétés de ces pièces dans le cas d’une localisation hors Europe. Ainsi, il est important de pouvoir adapter les conceptions rapidement et à moindre coût en prenant en compte les contraintes matériau/ process locales. Dans cette thèse, nous avons proposé une approche méthodologique permettant de prédire les caractéristiques mécaniques en fonction de la variabilité matériaux/ process en s'appuyant sur une étude expérimentale/ statistique de l’effet de la variabilité des principaux éléments d’alliage (Si, Cu, Mg) et des paramètres procédé (température de la coulée et pression d’injection) sur les propriétés mécaniques des alliages d’Al-Si moulés sous pression. La microstructure et le taux de porosités ont également été évalués. Cette méthodologie a abouti à la construction d’un outil de conception produit permettant de prédire les caractéristiques mécaniques dans le cas du changement de l’un (ou des) paramètres Matériau/ ProcessSecondary Al-Si alloys are widely used in automotive industry for engine blocks because they offer a considerable weight reduction whilst maintaining good mechanical properties. The ever-expanding internationalisation of production, with same stages of production processes spread across a number of countries to produce locally, causes however high variability in the casting products. The chemical composition of the same alloys and the working variables of the unchanged high-pressure die casting process (HPDC) may change for the same casting parts from one country to another, they can even sometimes vary from one manufacturing site to another within the same country. Designing for aluminium automotive components does call today for new deterministic design methods that are often achieved from European material and casting process databases, which can affect the properties of these parts in the case of a location outside Europe. Thus, it is important to adapt the design of die casting parts quickly and inexpensively by taking into account the material and process local constraints. In this work, a methodological approach which permits to predict mechanical properties as a function of material and process variability based on an experimental/ statistical study on the effect of the variability of the primary factors of alloying elements contents (Si, Cu and Mg) and HPDC process parameters (casting temperature and injection pressure) on mechanical properties of die cast aluminium alloys has been proposed. The microstructural features and the porosity level were also investigated and assessed. This approach has resulted in statistical design tool that will allow designers to make changes to the design of their casting and to industrialize them outside Europe
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Tharayil, Pradeep Ambareeksh, and Mohammadali Baradaran. "HPDC Die design for Additive Manufacturing : Simulation and Comparison of Thermal Stresses in HPDC die designed for Additive Manufacture." Thesis, Tekniska Högskolan, Högskolan i Jönköping, JTH, Industriell produktutveckling, produktion och design, 2019. http://urn.kb.se/resolve?urn=urn:nbn:se:hj:diva-43319.
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Additive manufacturing has a great potential to benefit die manufacture by shortening the lead time considerably and lifting the limitations on design complexity imposed by conventional manufacturing techniques. However, AM has its own requirements that together are known as Design for Additive Manufacturing and account for the process limitations. One of the significant requirements is mass efficiency of the design (it should be as light as possible). If it’s not fulfilled, AM won’t be able to make an economical solution or substitution despite having outstanding benefits. The present investigation has been framed with respect to such concern. This investigation attempts to draw a comparison between the performance of two design variants. Additionally, it has been tried to study the employed method, document implementation of the approach, and identify the challenges in accordance with design for additive manufacturing. Simulation of thermal stresses generated in die inserts for a given component during one cycle of high pressure die casting is presented. Initial design of the die inserts is subjected to redesign with the intention of mass reduction by incorporating honeycomb structure. Temperature evolution and resultant thermal stresses are analyzed for redesign and compared to those of original design. Simulation of high pressure die casting was carried out in MagmaSoft to obtain temperature history of die inserts and cast. Implicit nonlinear elastic fully coupled thermal displacement model was setup in Abaqus in which Magma results were used as input for stress calculation. Results show that according to our specific design, HPDC die with thin walled feature cannot withstand the thermal and mechanical load. However, with iterative analysis and proper topology optimization, a lightweight complex geometry die can be successfully made.
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Dézécot, Sébastien. "Caractérisation et modélisation du rôle des défauts microstructuraux dans la fatigue oligocyclique des alliages d'aluminium de fonderie : Application au procédé à modèle perdu." Thesis, Lyon, 2016. http://www.theses.fr/2016LYSEI148/document.
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Cette étude s’attache à caractériser les mécanismes d’endommagement qui mènent à la rupture d'un alliage AlSi7Cu3Mg élaboré par un procédé à modèle perdu sous sollicitations cycliques isothermes à 250°C en condition de plasticité généralisée. Sa caractérisation par micro-tomographie aux rayons X (µCT) a montré la complexité et l'aspect 3D marqué de la microstructure: présence de pores de morphologies complexes de grandes tailles (>1mm) et d'un réseau inter-connecté de particules. Un montage expérimental a été développé pour réaliser des essais de fatigue à haute température suivis in situ par µCT synchrotron. Ces essais ont mis en évidence les interactions entre les fissures et les éléments microstructuraux. Les fissures s'amorcent au cœur des éprouvettes à proximité des cavités de retrait au niveau de particules dures. La propagation des fissures apparaît corrélée à la rupture progressive des particules présentes en pointe de fissure. Ces observations ont été complétées par des essais de fissuration réalisés sur des éprouvettes macroscopiques. Un matériau sans pore (similaire au premier) à été produit pour dissocier le rôle des pores et celui des particules dans la fissuration du matériau. L’influence des pores se révèle du premier ordre pour l’amorçage. Des maillages éléments finis réalistes ont été générés pour réaliser des simulations élasto-viscoplastiques qui ont permis de proposer un critère d’amorçage. Les zones critiques vis-à-vis de l’amorçage de fissures sont celles où l’énergie de déformation inélastique est maximale. Les chemins de fissuration correspondent aux zones localisant les déformations inélastiques et présentant de fortes triaxialités des contraintes. L’ensemble de ces analyses a donc permis de proposer un scénario complet d’endommagement. Enfin, les essais sur éprouvettes macroscopiques ont permis de proposer un modèle pour décrire la vitesse de propagation des fissures et ceci pour les deux matériaux. Ce modèle, facilement utilisable en bureau d’étude, a été validé pour différents niveaux de chargementsThis study aims to characterize the fatigue damage mechanisms that lead to the rupture of a cast aluminum alloy AlSi7Cu3Mg produced by lost foam casting at 250°C under large scale yielding. Its characterization by X-ray micro-tomography (µCT) showed the complexity and the strong 3D aspect of its microstructure: large pores with complex shapes (>1mm) and a network of interconnected hard particles are present. An experimental setup was developed to perform high-temperature fatigue tests monitored in situ by synchrotron µCT. These tests revealed the interactions between cracks and microstructural elements. Cracks initiated, in the bulk, on hard particles located in the vicinity of shrinkage cavities. Cracks propagation appears to be correlated to the progressive rupture of particles present in front of the crack tip. These observations were completed by crack growth tests carried out on macroscopic specimens. A pore-free material (similar to the first) was produced to dissociate the role of pores and particles on the low cycle fatigue behavior of the material. Pores appear to be more critical regarding cracks initiation. Realistic finite element meshes have been generated to perform elasto-viscoplastic simulations which have allowed to propose a criterion for cracks initiation. Critical areas regarding cracks initiation are correlated to areas where the inelastic strain energies are maximum. The crack paths correspond to areas where inelastic strains are located and where the levels of stress triaxiality are high. All these informations allowed to propose a damage scenario. Finally, the tests on macroscopic specimens allowed to propose a crack growth speed model for both materials. This model, easily usable by engineers, have been validated for different loadings
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Schremmer, Michael. "Potentialanalyse zur Verwendung des Leichtmetalls Magnesium im Fahrwerk eines Automobils." Doctoral thesis, Technische Universitaet Bergakademie Freiberg Universitaetsbibliothek "Georgius Agricola", 2013. http://nbn-resolving.de/urn:nbn:de:bsz:105-qucosa-118583.
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Im Rahmen der Arbeit wurde das Potential von Magnesium für den Einsatz im Fahrwerk eines Automobils, am Beispiel der Querbrücke des Hinterachsträgers, ermittelt. Verschiedene Mg-Legierungen wurden im konventionellen und vakuumunterstützen Druckguss vergossen und der Al-Legierung vergleichend gegenübergestellt. Es wurden in einem ersten Schritt statische und zyklische Werkstoffkennwerte sowie Materialmodelle erforscht und bewertet. Verschiedene Lastfälle im Standard- und Sonderfahrbetrieb wurden durch statische und zyklische Betriebsfestigkeitssimulationen abgesichert. Konstruktive Bauteiloptimierungen waren notwendig um den Werkstoff Magnesium an die Anforderungen der Querbrücke anzupassen. Äußere Umwelteinflüsse im Fahrbetrieb machten ein Korrosionsschutzkonzept für die Querbrücke aus Magnesium notwendig. Untersucht wurden dabei verschiedene Maßnahmen zur Vermeidung von Kontakt- und Oberflächenkorrosion. Grundsätzlich scheint der Einsatz von Magnesium im Fahrwerk im Bereich mittlerer Betriebsbelastungen denkbar.
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Blombäck, Oscar, and Marcus Dahlén. "Minimering av porositet vid vakuumassisterad kallkammarpressgjutning av Al-Si : En fallstudie enligt DMAIC på Husqvarna Group." Thesis, Luleå tekniska universitet, Institutionen för ekonomi, teknik, konst och samhälle, 2021. http://urn.kb.se/resolve?urn=urn:nbn:se:ltu:diva-85097.
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Pressgjutna Al-Si komponenter förekommer mer och mer i förbränningsmotorer med syfte att reducera vikt och förbättra hållbarhet. Ett problem vid pressgjutning, en process kännetecknad av kostnadseffektivitet vid massproduktion, är porositetsbildning vilket kan resultera i läckage, strukturell svaghet och försämrad hållbarhet och livslängd för tillverkade komponenter. Då porer oftast bildas internt försvåras dessutom identifiering av potentiellt trasiga komponenter. Det är därför av vikt att finna parameterinställningar i pressgjutningsprocessen vilka konsekvent minimerar porositetsbildning. Ett företag som drabbas av återkommande porositets-relaterade defekter är Husqvarna Group. De använder vakuumassisterad pressgjutning för att, bland annat, producera motorcylindrar av Al-Si. Kassationsgraden, specifikt hänförbar till porositet, för en cylindermodell har under de senaste tre åren fördubblats vilket har resulterat i slöseri av produktionstid och kvalitetsbristkostnader. Vakuumassisterad pressgjutning kan beskrivas stegvis: (1) smält metall hälls i en cylindrisk fyllkammare, (2) en skottkolv trycker smältan mot ett mindre inlopp i låg hastighet för att undvika turbulens, samtidigt som vakuum ansätts i fyllkammare och gjutverktyg, (3) skottkolvshastigheten ökar markant vid en förinställd omslagspunkt, vilket spray-fyller gjutverktyget, och (4) högt tryck ansätts för att eftermata smälta till gjutverktyget när solidifiering sker. Syftet med detta examensarbete har varit att undersöka om och hur diverse parametrar, hänförbara till de nämnda processtegen, påverkar porositetsbildning i en industriell produkt. Därefter applicerades den erhållna processförståelsen för att identifera parametrar kritiska för porositetsbildning och slutligen rekommendera parameterinställningar som konsekvent minimerar porositetsgraden. Det experimentella upplägget bestod av två steg varav det första ämnade undersöka, via simulering, vilka av 6 parametrar som påverkade porositetsgraden utifrån en reducerad tvånivåers försöksdesign. Det andra steget var ett verkligt experiment i produktionsmiljö där de tre identiferade parametrarna från screening-experimentet varierades enligt en central-composite design. Analysen av experimenten resulterade i parameterinställningar som förväntas reducera porositetsgraden med över 70%. En lägre porositetsgrad kommer troligen reducera kassationsgraden av den undersökta cylindermodellen, vilket hade resulterat i finansiell besparing och effektivare produktion. I ett industriellt kontext bidrar detta exjobb huvudsakligen med en systematisk kvalitetsförbättrande metod för pressgjutna komponenter baserad i såväl simulerad som verklig miljö.Pressure die casted Al-Si components are increasingly found inside internal combustion engines, resulting in weight reduction and increased durability. Characteristic to die casting, commonly associated with cost-effective mass production, is the formation of pores which, if unnoticed, can cause leakage, structural deficiencies, and thus reduced durability and life-length of components. Pores commonly appear internally, making identification of faulty components difficult. Therefore, finding parameter settings in the die casting process that consistently minimizes the formation of pores is of importance. A company struggling with porosity-related defects is Husqvarna Group, currently using vacuum-assisted die casting to produce engine cylinders of Al-Si. Scrap-rate, specifically related to porosity, of a particular cylinder model has doubled in the last three years, causing waste of both precious production time and higher quality deficiency costs. A vacuum-assisted die casting process consists of several steps: (1) liquid Al-Si is poured into a cylindrical shot sleeve, (2) a plunger is moved towards a small gate, leading to the die cavity, at low velocity as to not cause turbulence, whilst vacuum is applied throughout the cavity and shot sleeve, (3) plunger velocity is increased substantially at a predetermined switch point, resulting in a spray-filling of the die cavity, and (4) high pressure is applied to continue the feed of molten metal into the cavity as solidification occurs. The purpose of the thesis has been to investigate if and how various parameters, related to the aforementioned four steps of the die casting process, impact the porosity amount in an industrial product. The acquired process knowledge was then applied to identify parameters affecting porosity and recommend settings that consistently minimize the porosity amount. The experimental procedure consisted of two steps: firstly, a screening experiment of six process parameters was made by simulating the die casting process according to a fractional factorial design. Secondly, a real-world experiment was conducted following a central-composite design by varying the three most impactful parameters from the screening experiment. Analysis of the experiments resulted in a selection of parameter settings, anticipated to reduce porosity by over 70%. A lower porosity amount will most likely reduce the scrap rate of the cylinder model, resulting in substantial savings and higher production efficiency. For practitioners, the main contribution of this thesis is a method of systematic quality-improvement to die-casted components by a combination of simulation experiments and real-world tests.
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Milhem, Luc. "Fonderie sous pression du cuivre : étude du procédé et caractérisation du matériau." Thesis, Normandie, 2018. http://www.theses.fr/2018NORMIR14.
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Ces travaux de recherche portent sur l’étude de l’injection du cuivre. Dans une optique d’amélioration des propriétés du cuivre injecté sous pression, deux grands thèmes de réflexion ont été abordés. La première voie de réflexion porte sur l’influence des paramètres de fusion et d’éléments d’alliages ajoutés en faible quantité sur les caractéristiques des démonstrateurs technologiques produits. La seconde partie discute de l’influence du procédé de fonderie en lui-même, notamment au travers de l’étude de deux paramètres : l’influence du régime d’écoulement du métal en fusion dans l’empreinte, et l’influence de l’emprisonnement de l’air sur les propriétés des pièces injectéesThis research focuses on the study of high pressure die casting (HPDC) of copper. In order to improve the properties of die-cast copper, two main issues were investigated. In the first part, attention is paid to the influence of melting parameters and of addition of alloying elements in small amounts on the characteristics of the specimen produced. The second part discusses the influence of the foundry process itself on properties of die cast part, in particular by studying two parameters : the metal flow type during cavity filling, and the air entrapment
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Koplík, Jiří. "Snížení nákladů na výrobu odlitku litého tlakovým litím pomocí aplikace vysokoteplotního separátoru." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2017. http://www.nusl.cz/ntk/nusl-318779.
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The diploma thesis is focuses on new technology in of high pressure die casting industry. Attention is paid in particular to heating, cooling and the influence of the die lubricants on the quality of castings. theoretical knowledge was applied in practise. The optimization of the production cycle was carried out using a high temperature die lubricant and subsequent evaluation on particular casts in foundry KOVOLIT Modřice a.s.
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Keller, Kevin. "Schockwellensynthese und Charakterisierung von Aluminiumnitrid mit Kochsalzstruktur." Doctoral thesis, Technische Universitaet Bergakademie Freiberg Universitaetsbibliothek "Georgius Agricola", 2014. http://nbn-resolving.de/urn:nbn:de:bsz:105-qucosa-131930.
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Die vorliegende Arbeit beschreibt die Ergebnisse der Synthese und Charakterisierung der Hochdruckphase von Aluminiumnitrid mit Kochsalzstruktur (rs-AlN). Die Versuche wurden mittels Schockwellensynthese unter Verwendung der „flyer-plate-Methode“ mit anschließender Probenrückgewinnung durchgeführt. Für verschiedene Aluminiumnitridpulver mit einer Ausgangsporosität k = rho_solid/rho_porous von 1,5 bis 2,5 wurde bei einem Druck von 15 bis 43 GPa die Phasenumwandlung von der Wurtzitstruktur (w-AlN) in die Kochsalzstruktur (rs-AlN) bewirkt. Es ist damit erstmals gelungen, rs-AlN mit dynamischen HP-HT-Methoden herzustellen und damit Probenmengen im Milligramm- bis Grammbereich zu erhalten. Dadurch ist es möglich Untersuchungen durchzuführen, die zur weiteren Erforschung und Charakterisierung des Materials beitragen sollen. Im Fokus liegen dabei insbesondere die Untersuchung der mechanischen, thermischen und chemischen Stabilität, um die Eignung des Materials zur Herstellung ultraharter Komposite zu evaluieren. Die geschockten Pulver bestehen aus einem Phasengemisch aus dem Ausgangsmaterial (w-AlN), der Hochdruckphase (rs-AlN), Aluminiumoxid und -oxynitriden, sowie amorphen Aluminiumhydroxiden. Die höchste Ausbeute an rs-AlN (~41 Ma% bei 2 mm Probenhöhe) kann bei Drücken von 24 GPa und einer Ausgangsporosität k von 2,1 erhalten werden. Anhand dem Auftreten verschiedener Al-O-N Phasen kann die Schocktemperatur für die einzelnen Versuche abgeschätzt werden (<1700 °C bis <2000 °C). Die Phasenumwandlung wird durch die Temperaturerhöhung aufgrund der Schockkompaktion der Pulver aktiviert. Als entgegenwirkender Prozess wurde die thermisch aktivierte Rückwandlung in die Niederdruckphase w-AlN aufgrund einer zu hohen Post-Schocktemperatur und einem zu langsamen Abkühlen der Probe postuliert. Daraus ergibt sich eine optimale Temperatur für den Versuchsaufbau von 1700 bis 1900 °C, bei der die höchsten rs-AlN Anteile beobachtet wurden. Eine Verringerung der Probenhöhe erhöht den Einfluss von Mehrfachreflektionen in der Probe und trägt damit zur Verbesserung der Umsetzung bei. Für drei Nanopulver (Kristallitgröße <25 nm) wurde die teilweise Umwandlung in die Kochsalzstruktur beobachtet, wohingegen für ein gröberes Nanopulver und ein Submikropulver (Kristallitgröße >45 nm) kein rs-AlN in den geschockten Proben nachgewiesen werden konnte. Es wird ein Stabilisierungsmechanismus der Kochsalzstruktur durch Kristallitgrößeneffekte vorhergesagt. Die Verringerung der Kristallitgröße führt zur Herabsetzung des Umwandlungsdrucks w-AlN -> rs-AlN. Es lässt sich daher schlussfolgern, dass für kleinere Partikel die Hochdruckmodifikation aufgrund der geringeren Entfernung vom chemischen Gleichgewicht bei Normalbedingungen stabilisiert werden kann, wohingegen für größere Kristallite die Rückwandlung in die Ausgangsphase geschieht. Weitere Stabilisierungsmechanismen wurden diskutiert. Mithilfe einer Rietveld-Verfeinerung der Röntgendiffraktogramme wurde die Gitterkonstante des rs-AlN mit a = 4,044 ± 0,001 Å und die Kristallitgröße mit 15,3 ± 0,2nm bestimmt. Die mittels hoch-aufgelöster Transmissionselektronenmikroskopie (TEM) bestimmte Kristallitgröße (10 bis 20 nm) ist in guter Übereinstimmung mit den Ergebnissen der Rietveld-Verfeinerung. Mit 27Al Kernspinresonanzspektroskopie (NMR) wurde die oktaedrische Al–N-Umgebung (AlN6) mit einer korrigierten chemischen Verschiebung von 2 ppm nachgewiesen. Anhand der IR-Spektren wird eine Al–N-Schwingungsbande des rs-AlN bei ca. 490 cm−1 vermutet. Dynamisch-thermische Untersuchungen zeigen, dass nanokristallines rs-AlN bei 600 °C beginnt zu Aluminiumoxid zu oxidieren und damit keine größere Beständigkeit im Vergleich zum w-AlN zeigt. Die thermisch aktivierte Rückwandlung des rs-AlN in die Niederdruckphase wurde ab 1200 °C (in Argon) bzw. 1100 °C (im Vakuum) bei einer Heizrate von 10 K/min beobachtet. Eine gute chemische Beständigkeit des Aluminiumnitrid mit Kochsalzstruktur gegenüber Wasser, Natronlauge und Säuren (HCl, H2SO4, H3PO4, HNO3 und Königswasser) wurde in Langzeit-Löslichkeitsversuchen nachgewiesenIn the present work the results of the synthesis and characterisation of the high-pressure phase of aluminium nitride with rocksalt structure (rs-AlN) are presented. The experiments were carried out with the flyer-plate-method with subsequently sample recovery. For different aluminium nitride powders with starting porosities k = rho_solid/rho_porous of 1.5 to 2.5 the phase transition from wurtzite structure (w-AlN) to the rocksalt structure (rs-AlN) was induced at a pressure of 15 to 43 GPa. This is to our knowledge the first succesful synthesis of rs-AlN with dynamic HP-HT methods. With this advance, samples in the milligram or gram range can be produced. Therefore further investigations to characterise the material are possible, especially the study of the mechanical, thermal and chemical stability to validate the potential for the production of ultrahard composites. The shocked samples consist of a phase mixture from the starting material (w-AlN), the high-pressure phase (rs-AlN), aluminium oxide and oxynitrides, as well as amorphous aluminium hydroxides. The highest yield of rs-AlN (~41 wt% at 2 mm sample height) can be obtained at a pressure of 24 GPa and a starting porosity k of 2.1. The shock temperature can be estimated by the formation of different Al-O-N phases (<1700 °C to <2000 °C). The phase transition is activated by the raise of temperature due to shock compression. A thermal activated reconversion to the low-pressure phase w-AlN caused by a high post-shock temperature and a slow cooling of the sample is postulated as a contrary process. This results in an optimum temperature of 1700 to 1900 °C for this set-up. A decrease of the sample height increases the influence of multiple reflections and therefore causes a better transformation. A partial conversion to rs-AlN was observed for three nanopowders (crystallite size <25 nm), whereas for a more coarse nanopowder and an submicronpowder (crystallite size >45 nm) no rs-AlN could be found in the shocked samples. A stabilisation mechanism of the rocksalt phase by crystallite size effects is predicted. The reduction of the crystallite size causes a decrease of the transition pressure for w-AlN -> rs-AlN. It can be concluded, that for smaller particles the high-pressure phase can be stabilised at ambient conditions on the basis of the smaller distance from equilibrium, whereas for larger particles the reconversion to the low-pressure phase occurs. By a Rietveld refinement of the X-ray diffractograms, the lattice constant of rs-AlN and the crystallite size was determined to be a = 4.044 ± 0.001 Å respectively 15.3 ± 0.2 nm. The crystallite size of rs-AlN (10 to 20 nm) determined with high-resolution transmission electron microscopy (TEM) is in good agreement with the results of the Rietveld refinement. The octahedral Al–Npolyhedral (AlN6) was demonstrated by 27Al nuclear magnetic resonance spectroscopy (NMR) with a corrected chemical shift of 2 ppm. Based on infrared spectroscopy (FTIR) an AlN vibration band at about 490 cm−1 is assumed. Dynamic thermal analysis show, that the rs-AlN starts to oxidise to alumina at 600 °C and thus have no greater resistance in comparison with w-AlN. The thermal activated reconversion of rs-AlN to the low-pressure phase starts at 1200 °C (in argon) respectively 1100 °C (under vacuum) at a heating rate of 10 K/min. The aluminium nitride with rocksalt structure shows a good chemical resistance against water, caustic soda and acids (HCl, H2SO4, H3PO4, HNO3 and aqua regia)
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Maurer, Simon Alexander. "Multidisziplinäre Formoptimierung modularer Grundgeometrien für Druckgussbauteile mit strömungs- und strukturmechanischen Zielfunktionen." Doctoral thesis, Technische Universitaet Bergakademie Freiberg Universitaetsbibliothek "Georgius Agricola", 2016. http://nbn-resolving.de/urn:nbn:de:bsz:105-qucosa-197331.
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Am Anfang des Entwicklungsprozesses eines Gussbauteils für die Automobilbranche steht klassischerweise die konstruktive Ausarbeitung und die Auslegung auf Zielgrößen, wie Festigkeit, Steifigkeit bzw. die Erfüllung der Crashlasten. Im nächsten Entwicklungsschritt wird, oftmals in Zusammenarbeit mit externen Lieferanten, das Werkzeugkonzept entwickelt und die Herstellbarkeit mit Hilfe von Gießsimulationen abgesichert. Bei der Fertigung verursachen streuende Prozessgrößen, wie etwa Geschwindigkeits- oder Temperaturniveaus, Schwankungen in der Leistungsfähigkeit des Endprodukts (z. B. lokale Bruchdehnung oder Zugfestigkeit). Maßnahmen zur Erhöhung der Prozessstabilität und zur Reduktion des Verschleißes konzentrieren sich oftmals auf die erfahrungsbasierte Verbesserung des Fertigungsprozesses und Anpassungen des Anguss- und Überlaufsystems. Größere Änderungen der Bauteilgeometrie sind häufig aus zeitlichen Gründen nicht mehr möglich. Das Ziel dieser Arbeit ist es daher, optimierte modularisierte Grundgeometrien, wie Rippen oder Umlenkungen, mit Hilfe von numerischen Formoptimierungen zu entwickeln, um diese schon von Anfang an in der Bauteilentwicklung zu berücksichtigen. Als Zielfunktionen dienen strömungs- und strukturmechanische Kenngrößen, um einerseits verschleißfördernde Mechanismen und füllungsbedingte Defekte zu reduzieren und andererseits die Beanspruchbarkeit zu erhöhen. Bei den Untersuchungen wird zusätzlich die Robustheit des Ergebnisses analysiert, um Verbesserungspotenziale auch bei streuenden Randbedingungen realisieren zu könnenThe virtual development process of an automotive casting part usually begins with classical design tasks and analyses of material strength, stiffness and crash load cases. In the next step, often in cooperation with external suppliers, the tooling concept is developed and casting simulations are used to ensure manufacturability. During manufacturing there is a scatter in process parameters, such as flow velocity or temperature levels, which in turn cause a scatter in the performance of the final product (e.g. local elongation at fracture or ultimate tensile strength). Means to increase process stability and yield are often limited to knowledge-based improvements of the manufacturing process parameters and adaptations of the gating and overflow system. Major changes to the part geometry are usually no longer possible due to project time constraints. Therefore it is the goal of this thesis to optimize modularized basic geometries, like ribs or bends, by using numerical shape optimizations and employ them right from the beginning of the part development process. For the objective functions of the optimizations the disciplines of fluid dynamic filling and the resulting structural behaviour are considered. In addition, the resulting shape is analyzed with regards to robustness towards scatter in manufacturing operating conditions. By using these new modularized geometries the overall robustness of the final product is expected to be increased
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Dini, Hoda. "As-cast AZ91D magnesium alloy properties : Effects of microstructure and temperature." Doctoral thesis, Tekniska Högskolan, Högskolan i Jönköping, JTH, Material och tillverkning, 2017. http://urn.kb.se/resolve?urn=urn:nbn:se:hj:diva-38148.
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Today, there is an essential need for lightweight, energy-efficient, environmentally benign engineering systems, and this is the driving force behind the development of a wide range of structural and functional materials for energy generation, energy storage, propulsion, and transportation. These challenges have motivated the use of magnesium alloys for lightweight structural systems. Magnesium has a density of 1.74 g/cm3, which is almost 30% less than that of aluminium, one quarter of steel, and almost identicalto polymers. The ease of recycling magnesium alloys as compared to polymers makes them environmentally attractive, but their poor mechanical performance is the primary reason for the limited adoption of these alloys for structural applications. The Mg-Al-Zn alloy AZ91D exhibits an excellent combination of strength, die-castability, and corrosion resistance. However, its mechanical performance with regard to creep strength, for example, at evaluated temperatures is poor. Moreover, very little is known about the correlation between its mechanical properties and microstructural features. This thesis aims to provide new knowledge regarding the role played by microstructure in the mechanical performance of the magnesium alloy. The properties/performance of the material in relation to process parameters became of great interest during the investigation. An exhaustive characterisation of the grain size, secondary dendrite arm spacing (SDAS) distribution, and fraction of Mg17Al12 was performed using optical and electron backscatter diffraction (EBSD). These microstructural parameters were correlated to the offset yield point (Rp0.2), fracture strength, and elongation to failure of the material. It was proposed that the intermetallic phase, Mg17Al12, plays an important role in determining the mechanical and physical properties of the alloy in a temperature range of room temperature to 190°C by forming a rigid network of intermetallic. The presence of this network was confirmed by studying the thermal expansion behaviour of samples of the alloy containing different amounts of Mg17Al12. A physically based constitutive model with a wide validity range was successfully adapted to describe the flow stress behaviour of AZ91D with various microstructures. The temperature-dependent variables of the model correlated quite well with the underlying physics of the material. The model was validated through comparison with dislocation densities obtained using EBSD. The influence of high-pressure die-cast parameters on the distortion and residual stress of the cast components was studied, as were distortion and residual stress in components after shot peening and painting. Interestingly, it was found that intensification pressure has a major effect on distortion and residual stresses, and that the temperature of the fixed half of the die had a slight influence on the component's distortion and residual stress.Numera finns det ett väsentligt behov av lätta, energieffektiva och miljövänliga tekniksystem. Detta behov är drivkraften för utveckling av ett brett utbud av material för energigenerering, energilagring, framdrivning och transport. Dessa utmaningar motiverade användningen av magnesiumlegeringar för lättviktskonstruktioner. Magnesium har en densitet på 1,74 g/cm3, vilket är ca 30% lägre än för aluminium, en fjärdedel av densiteten för stål och nästan i nivå med många polymerer. Då magnesiumlegeringar dessutom är lätta att återvinna, jämfört med polymerer, gör det dem miljömässigt attraktiva. Låga mekaniska egenskaper är den främsta orsaken till begränsad användning av dessa legeringar för lastbärande tillämpningar. Mg-Al-Zn-legeringen AZ91D uppvisar en utmärkt kombination av styrka, gjutbarhet och korrosionsbeständighet. Dess mekaniska egenskaper vid förhöjd temperatur, som tex kryphållfasthet, är låga. Dessutom är korrelationen mellan mikrostruktur och mekaniska egenskaper oklar. Denna avhandling syftade till att ge ny kunskap om mikrostrukturens roll för magnesiumlegeringars mekaniska egenskaper. Slutligen var materialets egenskaper i förhållande till processparametrar vid tillverkningen av stort intresse. En omfattande karaktärisering av kornstorleks-, sekundära dendritarmavstånds (SDAS)-fördelning och fraktion av Mg17Al12 utfördes med hjälp av optisk mikroskopering och diffraktion av bakåtspridda elektroner (EBSD). Mikrostrukturen korrelerades till sträckgränsen (Rp0.2), brottstyrkan och brottförlängningen. Det föreslogs att den intermetalliska fasen, Mg17Al12, spelar en viktig roll vid bestämning av legeringens mekaniska och fysikaliska egenskaper vid temperaturintervall från rumstemperatur upp till 190°C genom att bilda ett styvt nätverk av intermetaller. Uppkomsten av ett sådant nätverk stöddes genom en studie av den termiska expansionen av legeringen för olika fraktioner av Mg17Al12. En fysikalisk konstitutiv modell med ett brett giltighetsområde användes framgångsrikt för att beskriva det plastiska flytbeteendet hos AZ91D för olika mikrostrukturer. De temperaturberoende variablerna i modellen korrelerade ganska väl med materialets underliggande fysik. Modellen validerades genom att jämföra dislokationstätheten som predikterades av modellen och den med EBSD uppmätta dislokationstätheten. Påverkan av pressgjutningsparametrar på geometrisk tolerans och restspänning hos de gjutna komponenterna studerades. Vidare studerades geometrisk tolerans och restspänning av komponenter efter pening och målning. Intressant nog hade eftermatningsfasen en stor effekt på geometrisk tolerans och restspänningar. Dessutom hade temperaturen på den fasta formhalvan av verktyget även ett visst inflytande på komponentens geometriska tolerans och restspänning.
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Griveau, Jean-Christophe. "Etude de composés fermions lourds supraconducteurs sous hautes pressions : CECU2SI2 et UPD2AL3." Université Joseph Fourier (Grenoble), 1998. http://www.theses.fr/1998GRE10252.
Full textAbstract:
L'objet de cette these est l'etude des composes fermions lourds supraconducteurs cecu#2si#2 et upd#2al#3 sous pression dans leur phase normale et supraconductrice par resistivite electrique (p#a#c) et par susceptibilite magnetique alternative (#a#c). Les mesures ont ete effectuees en conditions quasi-hydrostatiques (steatite) et hydrostatiques (#4he). Les mesures par resistivite electrique se sont effectuees sous champ magnetique : un diagramme hc#2(t) a ete etabli sous pression pour les deux composes. Pour cecu#2si#2, l'etude sur monocristal en resistivite electrique sous champ magnetique et sous pression (b,t)#- a montre une augmentation drastique du champ critique dans le regime ii avec hc#2(o)5 t contre 2,1 t a pression nulle. Les ajustements du champ critique dans un modele de supraconducteur en limite propre et couplage faible indiquent une anisotropie liee sans doute a la surface de fermi non spherique (coefficient gyromagnetique <1) tandis que ceux en limite sale et couplage fort indiquent une changement de comportement net entre les regimes i et ii. La pente varie fortement sous pression : 25 k/t dans le regime i et 12 k/t dans le regime ii. Pour upd#2al#3, une etude en susceptibilite magnetique sous pression #a#c- sur polycristaux caracterises en transport a permis d'etablir : un diagramme t#c(p) montrant une forte diminution de la supraconductivite apres 6 gpa. On constate en resistivite sous champ et sous pression le maintient du regime de liquide de fermi. On constate peu de variation du champ critique sous pression : la masse effective liee a la pente a t#c presente un faible maximum autour de 5 gpa avant de diminuer fortement a partir de 6 gpa. Ces deux composes presentent deux aspects de l'interaction entre supraconductivite non conventionnelle et magnetisme : competition pour cecu#2si#2 et coexistence pour upd#2al#3.
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(9721637), Carl Kuang Yu Shi. "Electric Infrared Die heating for Aluminum High Pressure Die Casting." Thesis, 2020.
Find full textAbstract:
Casting is a substantial part of modern manufacturing and production, typically used in
the production of aluminum alloys. The high pressure die casting process is extremely
suitable for mass production. Due to the high volume, wasted time and resources during
the production cycle become more significant. Aluminum die castings require the die to
be at elevated temperatures to produce acceptable castings. When the inner surfaces of a
die are cold, the outer shell of the casting will cool too rapidly, and solidification of the
outer shell occurs before the aluminum has time to uniformly fill the cavities. Therefore,
without the die being within the proper temperature range, the castings produced will have
significant issues in porosity and casting incompleteness. Furthermore, stresses are
introduced to the casting surfaces when warm-up shots are used to raise the temperature
prior to production. In the present work, research is conducted on designing a heating
method for a casting die used in the manufacturing of an automotive transmission
intermediate plate. An electric, short wave infrared heating system is simple and effective
for the purpose. By utilizing an electric infrared heater in combination with a flat mirror
reflector, the aluminum high pressure die casting die was heated to 300 ◦C surface
temperature within 30 minutes. Further research can be done to optimize heat flux
distribution and minimize energy consumption.