Journal articles: 'Aluminium High Pressure Die Casting'

1

Gaspar, S., and J. Pasko. "Pressing Speed, Specific Pressure and Mechanical Properties of Aluminium Cast." Archives of Foundry Engineering 16, no. 2 (June 1, 2016): 45–50. http://dx.doi.org/10.1515/afe-2016-0024.

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Abstract Recent research in the process of aluminum alloy die castings production, which is nowadays deeply implemented into the rapidly growing automobile, shipping and aircraft industries, is aimed at increasing the useful qualitative properties of the die casting in order to obtain its high mechanical properties at acceptable economic cost. Problem of technological factors of high pressure die casting has been a subject of worldwide research (EU, US, Japan, etc.). The final performance properties of die castings are subjected to a large number of technological factors. The main technological factors of high pressure die casting are as follows: plunger pressing speed, specific (increase) pressure, mold temperature as well as alloy temperature. The contribution discusses the impact of the plunger pressing speed and specific (increase) pressure on the mechanical properties of the casting aluminum alloy.

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Rübner, M., M. Günzl, C. Körner, and R. F. Singer. "Aluminium–aluminium compound fabrication by high pressure die casting." Materials Science and Engineering: A 528, no. 22-23 (August 2011): 7024–29. http://dx.doi.org/10.1016/j.msea.2011.05.076.

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Ji, Shou Xun, Feng Yan, and Zhong Yun Fan. "Casting Development with a High Strength Aluminium Alloy." Materials Science Forum 828-829 (August 2015): 9–14. http://dx.doi.org/10.4028/www.scientific.net/msf.828-829.9.

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In the present paper, we introduce the development of casting an industrial component with a newly developed high strength aluminium alloy for high pressure die casting, including the introduction of property requirement, and the simulation results of temperature distribution, air entrapment, air pressure and the porosity potential in the casting, overflows and gating system. The microstructure and mechanical properties of the casting with satisfied quality are described under as-cast and heat-treated conditions.

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Galitu, Eugen Madalin, and George Constantin. "Increasing Performances in High Pressure Casting Process of Aluminium Alloys." Applied Mechanics and Materials 811 (November 2015): 63–74. http://dx.doi.org/10.4028/www.scientific.net/amm.811.63.

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The purpose of this paper is to present the influence of the casting parameters in the process of producing aluminium alloy components of gearbox housing type in automotive industry. The project has as objectives the minimization of the most common casting defects met in casting of gearbox housings through adjusting the parameters of the process. In order to minimize these defects, it was studied the casting speeds in phases I and II, multiplication pressure of phase III and the mould temperature that is influenced by both the cooling channels inside the mould and the spraying process of the mould (lubrication/cooling) that helps regulate the optimum temperature. The experimental results showed that the casting defects such as pores, cast in stages, shrinkage cavities, gas holes and tightness are significantly reduced by periodically controlling and correcting the specific casting parameters.

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Lumley, Roger N., and J. R. Griffiths. "Fatigue Resistance of Heat Treated Aluminium High Pressure Die-Castings." Advanced Materials Research 41-42 (April 2008): 99–104. http://dx.doi.org/10.4028/www.scientific.net/amr.41-42.99.

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High pressure die-casting (HPDC) is widely used as a cost-effective way to massproduce metal components that are required to have close dimensional tolerances and smooth surface finishes. Approximately 50%, by mass, of the aluminium castings produced worldwide are made by this manufacturing route. However, HPDC components are relatively porous compared with other types of castings and so cannot usually be conventionally heat treated to improve mechanical properties. This follows because during solution treatment (e.g. at 540°C for 8h), the pores expand, resulting in unacceptable surface blisters, distortion and poor mechanical properties. Recent work within the CSIRO Light Metals Flagship has revealed a heat treatment procedure by which the problems of blistering and distortion can be avoided [1]. As a result, large improvements in strength have been achieved, as compared with the as-cast condition. One uncertainty is the behaviour of heat treated HPDCs under cyclic stress and this paper investigates the fatigue properties of a common high pressure die-casting alloy, A380 (Al-8.5Si-3.5Cu). Comparisons are made between as-cast, T4 and T6 conditions. Fatigue strength is highest for the alloy aged to a T6 temper and ratios of fatigue strength to tensile strength for the as-cast, T4 and T6 conditions are constant at a value of approximately 0.6, which is particularly high for aluminium alloys.

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Vicario, Iban, Ignacio Crespo, Luis Plaza, Patricia Caballero, and Ion Idoiaga. "Aluminium Foam and Magnesium Compound Casting Produced by High-Pressure Die Casting." Metals 6, no. 1 (January 15, 2016): 24. http://dx.doi.org/10.3390/met6010024.

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P, Nagasankar, Sathiyamoorthy V, Gurusamy P, VinothKanna P, Manibharathi D, and Srikanth P. "Reduction of Blowholesin Aluminium High Pressure Die Casting Machine." International Journal of Engineering & Technology 7, no. 3.34 (September 1, 2018): 410. http://dx.doi.org/10.14419/ijet.v7i3.34.19336.

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The main objective of this research is to reduce the blowholes by analyzing the factors which are affected during the casting process. The process parameters are optimized and change is made in the design part to reduce the blowhole and to increase the efficiency of the high pressure die casting machines. Product manufactured from every manufacturing process shows some defects. For supplying quality product to the customer these defects must be reduced. In this work, an attempt is made to reduce the rejection due to the blowhole defect is found out through why-why analysis technique. Process capability of current high pressure die casting manufacturing process is checked. Manufacturing process found capable to manufacture the components. Current problem of blowhole defect is solved making an improvement in design of die which we insert. In gate directions are changed so as to obtain modified improved flow pattern. Using magma flow simulationsoftware existing and modified design has then been compared. It is found that, modified design shows superior results and using this, the defect of blowholes is minimized up to satisfactory level.

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Niu, X. P., B. H. Hu, I. Pinwill, and H. Li. "Vacuum assisted high pressure die casting of aluminium alloys." Journal of Materials Processing Technology 105, no. 1-2 (September 2000): 119–27. http://dx.doi.org/10.1016/s0924-0136(00)00545-8.

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Santos, Jorge, Anders E. W. Jarfors, and Arne K. Dahle. "Filling, Feeding and Defect Formation of Thick-Walled AlSi7Mg0.3 Semi-Solid Castings." Solid State Phenomena 256 (September 2016): 222–27. http://dx.doi.org/10.4028/www.scientific.net/ssp.256.222.

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Aluminium semi-solid castings have gained increased attention due to their superior mechanical properties, lower porosity compared to conventional high pressure die cast material. These characteristics suggests that semi-solid casting should be suitable to produce thick-walled structural components, yet most successful applications of semisolid casting have been for thin-walled components. There is a lack of understanding on filling and feeding related defect formation for semi-solid castings with thick-walled cross-sections. In the current study an AlSi7Mg0.3 aluminium alloy was used to produce semi-solid castings with a wall thickness of 10mm using a Vertical High Pressure Die Casting machine. The RheoMetalTM process was used for slurry preparation. The primary solid α-Al fraction in the slurry was varied together with die temperature. The evaluation of the filling related events was made through interrupted shots, stopping the plunger at different positions. Microscopy of full castings and interrupted test samples were performed identifying the presence of surface segregation layer, shear bands, gas entrapment, shrinkage porosity as well as burst feeding.

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10

Möller, Heinrich, Pfarelo Daswa, and Gonasagren Govender. "The Mechanical Properties of Rheo-High Pressure Die Cast Al-Mg-Si-(Cu) 6xxx Series Alloys." Solid State Phenomena 217-218 (September 2014): 61–66. http://dx.doi.org/10.4028/www.scientific.net/ssp.217-218.61.

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Near-net shape casting of wrought aluminium alloys has proven to be difficult due to a tendency towards hot tearing during cooling. Rheo-high pressure die casting (R-HPDC), has been shown to be an effective method of producing near-net shape wrought aluminium alloy castings. Limited information is available regarding the mechanical properties of age-hardenable wrought Al-castings produced by semi-solid metal forming. The purpose of this study is to investigate the effects of chemical composition and natural pre-ageing on the hardness and mechanical properties of rheo-HPDC 6xxx series Al-Mg-Si-(Cu) alloys in the T6 temper condition. The effects of the addition of Cu, as well as the (Mg+Si) content and Mg:Si ratio of the alloys are quantified. Alloys that are included are Cu-free 6004 and 6082, as well as Cu-containing 6013, 6111 and 6066. It is shown that the addition of Cu and excess Si result in higher hardness and strength. Natural pre-ageing has a significant effect (positive for 6004 and negative for the others) on the T6 properties. Good strength values can be achieved, but ductility is dependent on factors such as hot tearing during casting and incipient melting during solution heat treatment.

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Peti, Ferencz, and Gabriela Strnad. "The Effect of Squeeze Pin Dimension and Operational Parameters on Material Homogenity of Aluminium High Pressure Die Cast Parts." Acta Marisiensis. Seria Technologica 16, no. 2 (December 1, 2019): 7–12. http://dx.doi.org/10.2478/amset-2019-0010.

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Abstract The present paper is an experimental study on the squeeze pin effect on the high pressure die cast aluminium parts, as a way of improvement of material homogenity on various and big wall thickness castings. Squeeze is used in high pressure die casting technology for optimizing homogenity of big wall thicknesses of die cast parts working as structural, mechanical and hydraulic components, made of different aluminium alloys such AlSi alloys. The objective of this research is to highlight the primary and secondary effects of squeezing on the structural homogenity of high pressure die cast aluminium parts, as well as the dependence of the effects on the squeeze pin dimensions and the operating parameters.

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Özbay, İbrahim, Tamer Aydıner, Gürkan Yilmazoglu, Hafize Celik, Levent Aksel, Harun Yeni, Metehan Bayramoglu, and Erdem Aydogmus. "Aluminium High Pressure Die Casting Application on Rear Frame Rails." European Mechanical Science 3, no. 2 (June 20, 2019): 62–67. http://dx.doi.org/10.26701/ems.422299.

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13

Novakova, Iva, Jaromir Moravec, and Pavel Kejzlar. "Metallurgy of the Aluminium Alloys for High-Pressure Die Casting." Manufacturing Technology 17, no. 5 (October 1, 2017): 804–11. http://dx.doi.org/10.21062/ujep/x.2017/a/1213-2489/mt/17/5/804.

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14

Tharumarajah, Ambavalavanar, Dayalan R. Gunasegaram, and Paul Koltun. "Greenhouse Gas Emissions Attributable to High Pressure Die Casting." Materials Science Forum 618-619 (April 2009): 21–26. http://dx.doi.org/10.4028/www.scientific.net/msf.618-619.21.

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

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15

Savage, Gary, Lai Hua Wang, and Thang Nguyen. "Technologies to Improve Productivity and Reduce Tooling Costs in High Pressure Die Casting (HPDC)." Materials Science Forum 690 (June 2011): 112–15. http://dx.doi.org/10.4028/www.scientific.net/msf.690.112.

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Globalisation of supply chains for the automotive industry has made it increasingly difficult for developed economies to compete on price alone. In Australia, Nissan Casting has adopted technologies to reduce tooling costs and improve productivity of the die casting machines which use vacuum. Nissan Casting was experiencing cracking of their dies which extended into cooling lines, causing porosity outbreaks and shortened die life. CAST developed a repair technology called CASTrepair™ which is a relatively quick, simple and inexpensive repair technique for cracked cooling lines in HPDC dies. Also Nissan Casting is an extensive user of vacuum and a major issue was identified as unscheduled machine stoppages caused by aluminium blockages in the vacuum valves. The valves were of the mechanical shut off type and when they failed to shut off quickly enough aluminium entered the valve which then had to be changed. CAST developed CASTvac™ which is essentially a three dimensional chill vent with no moving parts required as a means to stop the aluminium entering the vacuum system. CASTvac™ has proven to be very reliable in production and has significantly reduced downtimes and toolroom maintenance at Nissan Casting. These two technologies, CASTrepair™ and CASTvac™, will be explained in detail with the latest developments in the technologies and associated benefits of their adoption.

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16

Dong, Xixi, Hailin Yang, Xiangzhen Zhu, and Shouxun Ji. "High strength and ductility aluminium alloy processed by high pressure die casting." Journal of Alloys and Compounds 773 (January 2019): 86–96. http://dx.doi.org/10.1016/j.jallcom.2018.09.260.

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Adianta, Andri Willy, Suprianto Suprianto, Arnius Daely, and Mikael F. Bangun. "Studi Fluiditas dan Karakteristik Aliran pada Pengecoran Al-Si Alloy Menggunakan Simulasi Numerik." Talenta Conference Series: Energy and Engineering (EE) 1, no. 1 (October 16, 2018): 007–12. http://dx.doi.org/10.32734/ee.v1i1.102.

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Aluminium silikon alloy merupakan paduan aluminium yang banyak digunakan dalam bidang teknik. Paduan ini memiliki kekuatan yang baik dan banyak diproduksi menjadi suatu komponen melalui proses pengecoran. Kandungan silikon dapat mengakibatkan penurunan fluiditas coran alumunium yang pada akhirnya akan menurunkan kualitas coran, fluiditas ini juga dipengaruhi temperatur pada saat penuangan alumunium cair. Penelitian ini bertujuan untuk mengetahui efek temperatur penuangan terhadap fluiditas, karakteristik aliran dan cacat coran pada pengecoran aluminium silikon alloy menggunakan cetakan pasir. Pengecoran dilakukan dengan gravity casting, analisa aliran simulasi meliputi distribusi kecepatan aliran, temperatur, tekanan, cacat permukaan dan fluiditas yang terjadi pada saat proses pengisian rongga cetak serta perbandingan fluiditas coran dan cacat permukaan pada eksperimental. Temperatur penuangan 685, 710, 735, 760 dan 785°C dengan ketebalan cetakan pola 1, 3, 5, 7, 9, dan 12 mm. Proses simulasi menggunakan software berbasis computational fluid dynamic. Hasil penelitian diperoleh temperatur tuang 785oC memiliki kecepatan aliran tertinggi yaitu sebesar ±0.145 m/s pada rongga 12 mm dan distribusi temperatur yang tinggi yaitu sebesar ±759 oC pada rongga 3 mm, sedangkan temperatur tuang 685oC memiliki distribusi tekanan yang tinggi yaitu sebesar ±107287 Pa pada rongga 6 mm. Cacat permukaan terbanyak pada temperatur tuang 785oC dan temperatur tuang 685oC paling sedikit. Fluiditas coran terbaik pada temperatur 785oC dimana rongga 12, 9, 7, 5 dan 3 mm terisi penuh dan 1 mm mencapai 181.4 mm. Aluminum silicon alloy is an aluminum alloy that is widely used in engineering. This alloy has good strength and plenty of it are produced into a component through the casting process. Silicon content could result in a decrease in fluidity of aluminum castings which in turn would reduce the quality of casting. This fluidity is also influenced by temperature at the time of pouring liquid aluminum. This study aims to determine the effect of pouring temperature on fluidity, flow characteristics and casting defects on aluminum alloy silicon casting by using sand mold. Casting was conducted by gravity casting, simulation flow analysis including flow velocity distribution, temperature, pressure, surface and fluidity defects that occured during the process of filling the mold cavity as well as the comparison of the fluidity of castings and surface defects in the experiment. Casting temperatures was 685, 710, 735, 760 and 785°C with a mold thickness of patterns 1, 3, 5, 7, 9 and 12 mm. The simulation process used software based on computational fluid dynamic. The result showed pouring temperature of 785oC had the highest flow velocity of ± 0.145 m/s in 12 mm cavity and a high temperature distribution of ± 759oC in cavity of 3 mm, while the pouring temperature of 685oC had a high pressure distribution of ± 107287 Pa in 6 mm cavity. Most surface defects occurred at pour temperature of 785oC and the least at pour temperature of 685oC. The best castings liquidity occurred at temperature of 785oC where the cavity of 12, 9, 7, 5 and 3 mm was fully filled and 1 mm reached 181.4 mm.

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Chauke, Levy, Pfarelo Daswa, Heinrich Möller, and Gonasagren Govender. "The Effect of Natural Pre-Ageing on the Mechanical Properties of Rheo-High Pressure Die Cast Aluminium Alloy 2139." Materials Science Forum 828-829 (August 2015): 244–49. http://dx.doi.org/10.4028/www.scientific.net/msf.828-829.244.

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Near-net shape casting of wrought aluminium alloys has proven to be difficult due to hot tearing. The Council for Scientific and Industrial Research (CSIR) has successfully processed wrought aluminium alloy 2139 into plate castings using the Rheo-high pressure die casting process (R-HPDC). Alloy 2139 is a Ag-containing aluminium alloy from the Al-Cu-Mg 2xxx series family. The addition of Ag enhances the age hardening response through the formation of co-clusters that act as precursors to the formation of plate-like Ω precipitates. These co-clusters typically form during natural ageing and 12-24 h of natural pre-ageing is normally specified before artificial ageing in Ag-containing Al-Cu-Mg alloys. The T6 hardness and tensile properties of R-HPDC 2139 alloy were investigated with and without natural pre-ageing. It is shown that there is no significant difference in both peak hardness and tensile properties in R-HPDC alloy 2139 with and without natural pre-ageing. The possible precipitation phenomena in both cases are discussed.

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Lumley, Roger N., Robert G. O'Donnell, Dayalan R. Gunasegaram, and Michel Givord. "Blister Free Heat Treatment of High Pressure Die-Casting Alloys." Materials Science Forum 519-521 (July 2006): 351–58. http://dx.doi.org/10.4028/www.scientific.net/msf.519-521.351.

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Conventionally produced high pressure die-cast (HPDC) components are not considered to be heat treatable because gases entrapped during the die-casting process expand during solution treatment causing unacceptable surface blistering. Components may also become dimensionally unstable. Both these effects prevent the heat treatment of die-castings as these phenomena are detrimental to the visual appearance, mechanical properties and utilisation of the component. Recent work has revealed a process window in which HPDC aluminium alloys that are capable of responding to age hardening may be successfully heat treated without encountering these problems. As a result, improvements of greater than 100% in the tensile properties are possible, when compared with the as-cast condition. The new heat treatment schedules are described for HPDC parts of different size and shape, the role of chemistry on ageing is discussed and microstructural development during heat treatment examined†.

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20

du Toit, Madeleine, Patronica Letsoalo, and Heinrich Möller. "Fusion Welding of Rheocast Semi-Solid Metal (SSM) Processed Aluminium Alloy 7017." Solid State Phenomena 192-193 (October 2012): 161–66. http://dx.doi.org/10.4028/www.scientific.net/ssp.192-193.161.

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Near-net shape casting of wrought aluminium alloys has proven to be difficult due to a tendency towards hot tearing during cooling. Rheocasting, or semi-solid metal (SSM) processing followed by high pressure die casting (HPDC), has recently been shown to be an effective alternative to conventional die casting, yielding near-net shape wrought aluminium alloy castings with less risk of hot tearing. This casting process involves pouring the liquid metal into a processing cup, which is then transferred into a coil for induction stirring and simultaneous forced air cooling. When the metal reaches the semi-solid casting temperature, the resultant slurry is transferred to a high pressure die casting machine and cast to near-net shape. This modifies the as-cast microstructure, yielding a more globular primary phase and results in mechanical properties in the -T6 condition closely approaching those of wrought material in the same condition. Little information is currently available on the response of SSM-HPDC material to welding. This project investigated the influence of autogenous laser and gas tungsten arc welding on the microstructure and mechanical properties of aluminium 7017 after rheocasting. It is possible to successfully weld this material without solidification or liquation cracking. The effect of welding on the rheocast microstructure in the heat-affected zone and weld metal was shown, and the hardness and tensile properties of the resulting joints in the as-welded condition were tested and related to the microstructures achieved.

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Li, Ji Qiang, Zhong Zhao, Zi Tian Fan, Zhi Xin Jia, Wen Liu, and Li Jun Liu. "Determination of Optimal Temperature for Defect-Free Casting of Aluminium in the LP-LFC Process." Applied Mechanics and Materials 101-102 (September 2011): 934–37. http://dx.doi.org/10.4028/www.scientific.net/amm.101-102.934.

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Fluidity of ZL101 aluminium alloys in the low-pressure lost foam casting (LP-LFC) process has been investigated by altering various temperature variables. The experimental results indicate that the LP-LFC process had fine fluidity, and the pouring temperature was lower than conventional lost foam casting. The effect of the metal temperature on the fluidity is marginal in the LP-LFC process. Excessive pouring temperature not only aggrandizes energy consumption but also deteriorates porosity defect. The success of casting cooling fin demonstrates the advantages of LP-EPC process in producing high-complicated castings.

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Lumley, Roger. "Design of Secondary Alloy Compositions for High Performance Aluminium Pressure Diecastings." Materials Science Forum 693 (July 2011): 247–55. http://dx.doi.org/10.4028/www.scientific.net/msf.693.247.

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High pressure die-casting (HPDC) is a widely used production technique for metal components that are required to have close dimensional tolerances and smooth surface finishes. Approximately 50% of the aluminium castings produced globally are manufactured by HPDC from secondary alloy and these are dominant in the automotive sector where they account for the majority of aluminium components present in each vehicle manufactured. Recently, it has been shown that industrially produced aluminium alloy high pressure diecastings (HPDC’s) can be successfully heat treated without encountering problems with surface blistering or dimensional instability. These processes may significantly improve the properties which develop from the alloys, thereby significantly increasing the scope of applications that may be realized. HPDC alloys however have not been developed specifically for heat treatment or the optimization of specific properties. In particular, recent work in Al-Si-Cu HPDC alloys has identified composition ranges of alloys for a) achieving yield strengths exceeding 400 MPa, b), rapid heat treatment that minimizes cost / cycle times, and c) high strength combined with elevated ductility levels. The role of alloying elements, composition limits and effects on mechanical property development are discussed.

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Watson, Robert, Tayeb Zeguer, Simon Ruffle, and William D. Griffiths. "Application of a Novel Entrainment Defect Model to a High Pressure Die Casting." Advanced Materials Research 922 (May 2014): 801–6. http://dx.doi.org/10.4028/www.scientific.net/amr.922.801.

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Aluminium High Pressure Die Castings are economical to produce in high volumes. However, as greater structural demands are placed on such castings, a more detailed understanding is required of the defects which limit their strength. The process is prone to high levels of surface turbulence and fluid break-up, resulting in the entrainment of air into the liquid metal, which may manifest as trapped air porosity or bifilm defects in the finished part. A novel algorithm was developed and integrated into a commercial computational fluid dynamics (CFD) package, to model mould filling, and the formation and transport of such entrainment defects. A commercial High Pressure Die Casting was simulated using this algorithm, to illustrate its application. Castings were also produced, and the results of tensile testing were summarised in the form of Weibull statistics. It was found that where the algorithm predicted a greater quantity of entrained surface film, a reduction in UTS of about 10% was also observed.

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Rasmussen, N. W., P. N. Hansen, and S. F. Hansen. "High pressure die casting of fibre-reinforced aluminium by preform infiltration." Materials Science and Engineering: A 135 (March 1991): 41–43. http://dx.doi.org/10.1016/0921-5093(91)90534-t.

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Peti, Ferencz, and Petru Serban. "Effect of Material Segregations Due to Squeeze Parameters on Mechanical Properties of High Pressure Diecast Parts." Acta Marisiensis. Seria Technologica 17, no. 1 (June 1, 2020): 4–10. http://dx.doi.org/10.2478/amset-2020-0002.

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AbstractThis article is a research on the effect of material segregations due to squeeze parameters on mechanical properties of high pressure die cast parts. The technology of squeezing is applied in high pressure die casting technology with the aim to improve the internal material health of the castings from aluminium alloys, such as AlSi9Cu3(Fe), components incorporated in assemblies as mechanical and hydraulic parts. The objective of this article is to determinate the influence of the secondary effects of squeeze technology on the mechanical properties of parts produced from AlSi9Cu3(Fe) alloys, with HPDC technology.

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Azhagan, M. Thirumal, B. Mohan, and A. Rajadurai. "Experimental Study of Squeeze Casting of Aluminium Alloy AA6061." Applied Mechanics and Materials 766-767 (June 2015): 422–26. http://dx.doi.org/10.4028/www.scientific.net/amm.766-767.422.

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The squeeze casting of aluminium alloys is a rapidly developing technical process that offers the potential for widespread utilization and growth. Squeeze casting process is the result of search of new production processes which are capable of producing components with high integrity. Squeeze casting also called as liquid metal forging combines the advantages of both casting and forging in one operation. Squeeze casting process is suited for all melting ranges of metals. But nowadays, light weight materials like aluminium and magnesium are mostly used in the aerospace and automotive industries. In this attempt, Squeeze casting of AA6061 was done by varying the process parameters such as squeeze pressure at three levels(40 MPa, 80 MPa and 120 MPa) , die preheat temperature at 200 °C and pressure applied duration at 15 seconds respectively and the components were produced. The specimens were made from these components and they were tested for tensile strength and fatigue life. It was observed that the tensile strength and fatigue life exhibited by the components were enhanced with the increase in squeeze pressure.

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Jie, Wan Qi, Xin Lei Li, and Qi Tang Hao. "Counter-Gravity Casting Equipment and Technologies for Thin-Walled Al-Alloy Parts in Resin Sand Molds." Materials Science Forum 618-619 (April 2009): 585–89. http://dx.doi.org/10.4028/www.scientific.net/msf.618-619.585.

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A counter-gravity casting equipment (CGCE) has been developed, which is specially designed for the production of large-size thin-walled high-quality aluminum alloy parts with resin sand molds. In this equipment, molten metal will be pushed upward counter-gravity into the mold at predetermined rate by compressed air, and solidified at an increased pressure. The equipment uses assembled valve system developed ourselves, and has sensitive pressure-adjusting property. All of the casting parameters, including filling rate, pressure-exerting sequence, pressure hold time etc., can be closely controlled by a self-designed computer program. Up to 2 ton casting can be produced with the equipment. Compared to the castings produced under conventional gravity conditions, the castings under counter-gravity condition have generally high soundness, higher tensile strengths and ductility. The pinhole defects are also degraded obviously. The equipment and the technology have been widely adopted by several users in China for the production of large-size thin-walled aluminum alloy castings with high property requirements.

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Dulyapraphant, Pongsak, Ekkachai Kittikhewtraweeserd, Nipon Denmud, Prarop Kritboonyarit, and Surasak Suranuntchai. "Applications of Squeeze Casting for Automobile Parts." Materials Science Forum 773-774 (November 2013): 887–93. http://dx.doi.org/10.4028/www.scientific.net/msf.773-774.887.

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

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Pałyga, Ł., M. Stachowicz, and K. Granat. "Effect of Selected Parameters of Pressure Die Casting on Quality of AlSi9Cu3 Castings." Archives of Foundry Engineering 15, no. 2 (June 1, 2015): 85–90. http://dx.doi.org/10.1515/afe-2015-0044.

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Abstract This paper presents the results on the effects of die-casting process on the strength parameters of castings of the aluminium AlSi9Cu3 alloy belonging to the group of EN AB-46000, made on renovated high pressure die-casting machine. Specimens for quality testing were taken from the places of the casting most loaded during the service. The aim of a research was to prove how the new die-casting process control capabilities influence on the tensile strength of the cast material defined as a value of the breaking force of the specimens. It has been found that it is possible to specify a set of recommended settings valves of second (II) and third (III) phase, which are responsible for filling the metal mould on die-casting pressure machine. From the point of view of the finished cast element, it was noticed that exceeding the prescribed values of valve settings does not bring further benefits and even causes unnecessary overload and reduce the durability of the mold. Moreover, it was noticed that reduction of the predetermined setting of the second phase (II) valve leads to the formation of casting defects again.

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Chauke, Levy, Heinrich Möller, and Gonasagren Govender. "Anodising of Aluminium Alloy Plates from Different Series Produced by Rheo-High Pressure Die Casting." Solid State Phenomena 217-218 (September 2014): 247–52. http://dx.doi.org/10.4028/www.scientific.net/ssp.217-218.247.

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Anodising of aluminium alloy components can be used for decorative purposes and to enhance the corrosion and wear resistance. In this research, four different Al-alloy series namely Al-Cu-Mg (2xx/2xxx), Al-Si-Mg (3xx), Al-Mg-Si (6xxx) and Al-Zn-Mg-Cu (7xxx) were used to produce plates by rheo-high pressure die casting (R-HPDC). Castings produced by R-HPDC suffer from a surface liquid segregation (SLS) phenomena. This surface layer is enriched with alloying elements and it is shown to have different characteristics as compared to the bulk material. The study focused on the anodisability of plates from the four series produced by R-HPDC with and without the SLS. The samples were anodised at a commercial facility. The oxide layer thickness and homogeneity were studied using optical microscopy.

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Pereira, Filipe, and Martin Williams. "Reducing Non Value Adding Aluminium Alloy in Production of Parts by High Pressure Die Casting Using High Temperature Die Manufacturing Material." Materials Science Forum 828-829 (August 2015): 93–99. http://dx.doi.org/10.4028/www.scientific.net/msf.828-829.93.

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The difficulties and issues associated with the economics of the process and die life in casting aluminium alloys, as experienced by the high pressure die casting industry, were reasons behind undertaking this research project. The use of a tungsten alloy able to withstand high temperature process conditions without the welding problems experienced by standard die construction materials, such as H13, was examined in an extensive series of casting trials. The importance of operating dies at elevated temperatures to minimize heat checking has been demonstrated previously, both through theoretical thermal modelling and experimentation. This paper describes both aspects of die life extension and possibilities to reduce the amount of alloy material used in the cast part feed system, including overflows. CSIR intends using the results of this research for further development and application of high temperature die construction materials in high pressure die casting processes of light metal alloys.

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Weiss, David, and Michael Black. "The Use of High Pressure Direct Squeeze Casting for Semi-Solid Processing of Aluminum Base Nano Composites." Solid State Phenomena 192-193 (October 2012): 72–75. http://dx.doi.org/10.4028/www.scientific.net/ssp.192-193.72.

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The production of nano-reinforced aluminium alloys in volume and quality suitable for subsequent shape casting has been problematic. Large specific surface area and high interfacial energy of the particles combined with high surface tension of the aluminium melt makes it difficult to add appreciable numbers of particles to the melt, even when later de-agglomerated by techniques such as ultrasonic cavitation. The objective of this work was to develop a technique to incorporate particles using pressure applied while the alloy was in a semi-solid state. The composites produced could be used as a master alloy to inoculate large batches of metal for subsequent casting using any suitable technique. The results show excellent distribution of 50 nm alumina particles in 2014 material. The procedure appears to have broad applicability to a full range of aluminium alloys and particle reinforcements.

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Franke, Alois, and John L. Jorstad. "THINCAST^TM; Providing Strong, Lightweight Castings for Automobiles and Other Applications." Solid State Phenomena 217-218 (September 2014): 294–301. http://dx.doi.org/10.4028/www.scientific.net/ssp.217-218.294.

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Aluminium Rheinfelden has improved the competitiveness of semi solid processing by developing a casting process & alloy combination that is capable of ultra thin, ultra light parts having attractive engineering properties without need for full heat treatment. The THINCASTTM rheocasting process, together with Rheinfeldens Magsimal-59 alloy has been demonstrated capable of producing moderate sized castings with only 1-2 mm wall sections, thus providing a 30-50% reduction in traditional-process part weight. THINCASTTM can be adapted to a variety of die casting machines and will enable competitively improving the quality of conventional high pressure die castings as well as creating entirely new applications.

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Norwood, A. J., P. M. Dickens, R. C. Soar, and R. A. Harris. "Surface temperature of tools during the high-pressure die casting of aluminium." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 221, no. 12 (December 2007): 1659–64. http://dx.doi.org/10.1243/09544054jem745.

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35

Bhagat, R. B. "High pressure squeeze casting of stainless steel wire reinforced aluminium matrix composites." Composites 19, no. 5 (September 1988): 393–99. http://dx.doi.org/10.1016/0010-4361(88)90127-9.

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36

DARGUSCH, M. S., A. HAMASAAID, G. DOUR, and X. YAO. "MEASUREMENTS OF HEAT LOSSEST DURING SOLIDIFICATION OF LIGHT MEALS." International Journal of Modern Physics B 23, no. 06n07 (March 20, 2009): 802–7. http://dx.doi.org/10.1142/s0217979209060051.

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This paper describes the application of a new in-cavity thermal measurement method to determine the heat flux and calculate heat losses during high pressure die casting of aluminium A380 alloy and the magnesium alloy AZ91-D. Thermal management of the die is a critical concern in high pressure die casting and the development of microstructures after solidification. Detailed measurements were performed using infra-red probes linked to pyrometric chains and thermocouple arrays that accurately determine both casting and die surface temperatures enabling the determination of heat flux densities and interfacial heat transfer coefficients and the rapid evolution of these values with time during high pressure die casting of these alloys. The energy losses during the spray cycle can then be determined by integrating the heat flux curves for the duration of the spray application. The significance of the findings presented in this investigation arise from the uniqueness of the measurement methods applied to the determination of heat flux during the high pressure die casting of both magnesium and aluminium alloys. In particular the detailed knowledge of the thermal characteristics occurring at the cavity fill stages of the die casting process achieved through the selection of an array of fine rapid-response thermocouples integrated in one sensor along with the light pipe/pyrometric chain have enabled the accurate measurement of both the die and metal surface temperatures through the entire die casting cycle enabling the calculation of heat losses during solidification and processing.

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Teichmann, Fabian, Arne Ziemer, Martin Leitner, Jonas Hensel, and Klaus Dilger. "Linear Elastic FE-Analysis of Porous, Laser Welded, Heat Treatable, Aluminium High Pressure Die Castings Based on X-Ray Computed Tomography Data." Materials 13, no. 6 (March 20, 2020): 1420. http://dx.doi.org/10.3390/ma13061420.

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The welding of aluminium high pressure die castings is a well known and broadly investigated challenge in various fields of industry and research. Prior research in this specific field mainly focused on the optimisation of the welding and the casting process and on the cause of the frequently occurring porosity and incomplete fusion phenomena, whereas the impacts of these defects have hardly been addressed. Therefore, the underlying study presents the investigation of weldments in EN AC-AlSi10MnMg high pressure aluminium die castings by linear elastic finite element analysis based on X-ray computed tomography as a novel approach. Hereby, four laser weldments with differing surfaces and pore contents were investigated by X-ray computed tomography and tensile testing. Based on the voxel datasets of the porous weldments, triangular finite element meshes were generated and a numerical finite element analysis was conducted. Good agreement of the stress–strain curves between the simulations and the experiments was achieved.

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Skorulski, G. "3DP Technology for the Manufacture of Molds for Pressure Casting." Archives of Foundry Engineering 16, no. 3 (September 1, 2016): 99–102. http://dx.doi.org/10.1515/afe-2016-0058.

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Abstract The paper presents the use of rapid prototyping technology of three dimensional printing (3DP) to make a prototype shell casting mold. In the first step, for identification purposes, a mold was prepared to enable different alloys to be cast. All molds being cast were designed in a universal CAD environment and printed with the zp151 composite material (Calcium sulfate hemihydrate) with a zb63 binder (2-pyrrolidone). It is designated to be used to prepare colourful models presenting prototypes or casting models and molds. The usefulness of 3DP technology for use with copper alloys, aluminum and zinc was analyzed. The strength of the mold during casting was assumed as a characteristic comparative feature in the material resistance to high temperature, the quality of the resulting casting and its surface roughness. Casting tests were carried out in vacuum – pressure casting. The casting programs applied, significantly increased the quality of castings and enabled precise mold submergence. Significant improvement was noted in the quality compared to the same castings obtained by gravity casting.

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Niu, X. P., K. K. Tong, B. H. Hu, and I. Pinwill. "Cavity pressure sensor study of the gate freezing behaviour in aluminium high pressure die casting." International Journal of Cast Metals Research 11, no. 2 (September 1998): 105–12. http://dx.doi.org/10.1080/13640461.1998.11819264.

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D’Errico, Fabrizio, Daniele Casari, Mattia Alemani, Guido Perricone, and Mauro Tosto. "INDUSTRIAL SEMISOLID CASTING PROCESS FOR SECONDARY ALUMINIUM ALLOYS FOR DECARBONISING LIGHTWEIGHT PARTS IN AUTOMOTIVE SECTOR." MATEC Web of Conferences 326 (2020): 06007. http://dx.doi.org/10.1051/matecconf/202032606007.

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The life cycle holistic approach for the automotive sector highlighted how much important is working on decarbonisation of Al casting processes to produce vehicle components. Broadening the use of recycled aluminium alloys, instead of high energy intensive primary aluminium alloys, is key for environment preservation. While primary aluminium alloys are preferred by automotive original equipment manufacturers (OEMs) because impurities (mainly Fe) present in secondary aluminium alloys might cause fatigue properties decay, a new semisolid state process route has been developed at Brembo to drastically reduce the sensitivity of cast aluminium to Fe impurities. Based on these premises, during the CRAL European project in the framework of the LIFE Programme, an industrial prototype machinery - a vertical high pressure die casting machine - has been designed and constructed to inject secondary aluminium in the semisolid state. A number of A357 Fe-enriched brake callipers manufactured via the new process route have been fully investigated by fatigue tests, SEM and OM analyses in order to validate the new eco-sustainable product compared to conventional ones manufactured with primary aluminium by gravity casting.

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Dubják, Ján, Ján Piteľ, and Mária Tóthová. "Diagnostics of Aluminum Alloys Melting Temperature in High Pressure Casting." Key Engineering Materials 669 (October 2015): 110–17. http://dx.doi.org/10.4028/www.scientific.net/kem.669.110.

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The high pressure casting process is a well-established way for the manufacture of non-ferrous components. Temperature is important technological parameter of production that affects the structure and quality of castings. Using continual exact measurement of alloy temperature is the best approach for predicting structures quality problems.Temperature measurement system also would help to acquire feedback from the manufacturing process so as to prevent possible defects in next phases of manufacturing. For this measurement we used thermocouple type „K“ in protective tube from graphite. It is necessary for correct process to know true values of temperature. For diagnostics we used procedures of SPC (StatisticalProcess Control) and Microsoft Excel 2007 graphic tools.

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Daswa, Pfarelo, Heinrich Moller, and Gonasagren Govender. "Overageing Characteristics of Alloy A356 and Al-Mg-Si Casting Alloys." Solid State Phenomena 285 (January 2019): 75–80. http://dx.doi.org/10.4028/www.scientific.net/ssp.285.75.

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Al-Si-Mg casting alloys, such as Al-7Si-0.3Mg alloy A356, are heat treatable and can be precipitation hardened to the T6 temper condition. However, Al-Mg-Si casting alloys (5xx series) are generally not considered to be heat treatable. These 5xx series castings are known for good castability and good resistance to corrosion, especially in marine environments. This paper investigates the extent to which 5xx series alloys could possibly be artificially aged. The influences of artificial ageing time on the overageing characteristics of both Al-Mg-Si and A356 casting alloys have been studied. A356 aluminium alloy castings were produced using the CSIR rheo-high pressure die casting process (R-HPDC). Al-Mg-Si alloys were cast using permanent mould casting. The rate of overageing of these alloys is of importance for potential higher temperature applications. The overageing characteristics of Al-Mg-Si and A356 aluminium alloys have been investigated at an artificial ageing temperature of 190°C for ageing times up to 128 hours. It is shown that the rate of overageing of Al-Mg-Si casting alloys is lower than for alloy A356. This could possibly result in the use of these alloys in applications at temperatures that are higher than where alloy A356 can be employed. It also allows the possibility of using the 5xx series alloys as an alternative to other Al-alloys for R-HPDC applications.

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Law, Madeleine, Christopher Neil Hulme-Smith, Taishi Matsushita, and Pär G. Jönsson. "Assessment of Mechanisms for Particle Migration in Semi-Solid High Pressure Die Cast Aluminium-Silicon Alloys." Journal of Manufacturing and Materials Processing 4, no. 2 (May 25, 2020): 51. http://dx.doi.org/10.3390/jmmp4020051.

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

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Dolata, A. J. "Centrifugal Castings Locally Reinforced with Porous AL2O3 Preform." Archives of Metallurgy and Materials 59, no. 1 (March 1, 2014): 345–48. http://dx.doi.org/10.2478/amm-2014-0057.

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Abstract The main objective of presented researches were tests of infiltration of the porous ceramic preforms at the pressure in centrifugal casting process. Make an assumption that the porous preform will be create the local reinforcement layer in specific area of the casting. For investigations the alumina porous ceramic preforms were applied (Al2O3). The pressure to infiltrate molten aluminum alloy into ceramic preforms was generated by centrifugal force. The structure of composites was examined by light and electron microscope. The investigations of composites microstructure exhibited high degree of infiltration of spherical macropores in Al2O3 ceramic preforms by the molten aluminium alloy. On the basis of structural studies has been shown that centrifugal force is effective as a driving force for the infiltration of porous preforms.

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Konopka, Z., and A. Pasieka. "Tribological Properties of AlSi11-SiCp Composite Castings Produced by Pressure Die Casting Method." Archives of Foundry Engineering 14, no. 3 (August 8, 2014): 37–42. http://dx.doi.org/10.2478/afe-2014-0058.

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Abstract The measurement results concerning the abrasive wear of AlSi11-SiC particles composites are presented in paper. The method of preparing a composite slurry composed of AlSi11 alloy matrix and 10, 20% vol.% of SiC particles, as well as the method of its high-pressure die casting was described. Composite slurry was injected into metal mould of cold chamber pressure die cast machine and castings were produced at various values of the piston velocity in the second stage of injection, diverse intensification pressure values, and various injection gate width values. Very good uniform arrangement of SiC particles in volume composite matrix was observed and these results were publicated early in this journal. The kinetics of abrasive wear and correlation with SiC particles arrangement in composite matrix were presented. Better wear resistance of composite was observed in comparison with aluminium alloy. Very strong linear correlation between abrasive wear and particle arrangement was observed. The conclusion gives the analysis and the interpretation of the obtained results.

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Long, Alastair, David Thornhill, Cecil Armstrong, and David Watson. "Predicting die life from die temperature for high pressure dies casting aluminium alloy." Applied Thermal Engineering 44 (November 2012): 100–107. http://dx.doi.org/10.1016/j.applthermaleng.2012.03.045.

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47

Pereira, Filipe. "Operational Cost Analysis of a Typical South African High Pressure Die-Casting Business." Advanced Materials Research 1019 (October 2014): 152–59. http://dx.doi.org/10.4028/www.scientific.net/amr.1019.152.

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This paper looks at the issue and influence of the die cost on a typical Aluminium die casting business. High pressure die casting (HPDC) is a manufacturing process used to produce components in a near finished shape with a reasonable good surface aspect, dimensionally accurate and within a short period off time or production cycle. The die is at the heart of the HPDC business and is unique to each component to be produced. A full business analysis was done and the full die cost share was extracted as part of a life cycle inventory of the HPDC manufacturing process. The inventory accounted for the energy metal and other inputs flows through the foundry. Die casting uses significant quantities of energy, as well as materials like oil-based lubricants and cooling water. Costs associated with part finishing are also considered due to the direct link between die manufacture and design and resulting finishing operations required.

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Liu, Mengyun, Zhan Zhang, Francis Breton, and X. Grant Chen. "Investigation of the Quench Sensitivity of an AlSi10Mg Alloy in Permanent Mold and High-Pressure Vacuum Die Castings." Materials 12, no. 11 (June 11, 2019): 1876. http://dx.doi.org/10.3390/ma12111876.

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The quench sensitivities of an AlSi10Mg alloy in permanent mold (PM) and high-pressure vacuum die (HPVD) castings were investigated with time–temperature–transformation and time–temperature–property diagrams using an interrupted quench technique. The quench-sensitive temperature range of the HPVD casting sample is 275–450 °C, and its nose temperature is 375 °C. The quench-sensitive range of the PM casting sample is 255–430 °C, and the nose temperature is 350 °C. The mechanical strength versus the cooling rate in both casting samples were predicted via a quench factor analysis and verified experimentally. The critical cooling rate of the HPVD casting sample is 20 °C/s whereas it is 17 °C/s for the PM casting sample. With a shorter critical time, higher nose temperature, and higher critical cooling rate, the HPVD casting sample exhibits a higher quench sensitivity than the PM casting sample. The differences in the quench sensitivities of the AlSi10Mg alloy due to the different casting processes is explained via the different precipitation behavior. At the nose temperature, coarse β-Mg2Si precipitates mainly precipitate along the grain boundaries in the HPVD casting sample, whereas rod-like β-Mg2Si precipitates distribute in the aluminum matrix in the PM casting.

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Charoenrut, Kasem, and Chaiyasit Banjongprasert. "Effects of Processing Parameters on Microstructure and Properties of Aluminum-Silicon Alloy ADC12." Key Engineering Materials 777 (August 2018): 300–305. http://dx.doi.org/10.4028/www.scientific.net/kem.777.300.

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Aluminum-Silicon Alloy, ADC12 is one of the most popular alloys for pressure die casting due to its high castability and high productivity. ADC12 is a hypoeutectic aluminum-silicon alloy that contains 10-12wt% of Si and has an occasional problem for a mechanical properties failure such as crack and shrinkage porosity. This study presents the investigation of the microstructure of ADC12 parts produced by pressured die casting with different process parameters and chemical compositions. The microstructure was observed using optical microscopy (OM) and scanning electron microscopy (SEM) with energy – dispersive X-ray (EDX) and electron backscatter diffraction (EBSD) to determine phases, grain, and crystallographic information in order to understand the microstructural evolution after die casting with different process conditions. Changes in casting pressure and a reduction of iron content contributed to enhanced mechanical properties and less shrinkage porosity. This was due to different processing parameters, mainly casting pressure. The average grain size of aluminum matrix was also reduced due to a higher pressure during casting with a moderately fast cooling rate.

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Nguyen, Thang, Vu Nguyen, Morris Murray, Gary Savage, and John Carrig. "Modelling Die Filling in Ultra-Thin Aluminium Castings." Materials Science Forum 690 (June 2011): 107–11. http://dx.doi.org/10.4028/www.scientific.net/msf.690.107.

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This work aims to develop flow and thermal control methods for the high pressure die casting (HPDC) of very thin-walled aluminium components where thicknesses are predominantly less than 1 mm. One specific aim includes developing advanced modelling capability using CFD software to predict the complex structure of the metal flow in the die and the casting solidification. The modelling based on FLOW-3D started initially with a fluidity die study to establish several key parameters in HPDC modelling through experimental validation. A new test casting geometry has been designed in the form of a shallow tray with other features such as changes in curvature, fins and bosses. The casting thickness can be made variable in the die. The experimental work was conducted on a 250-tonne HPDC machine. Initial models of molten metal flow in the die cavity based on a runner design for casting thicknesses between 1.5 mm and 1 mm are presented. The detailed model required a very large mesh of very small elements, and more accurate physical parameters which may not have been previously available.

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Journal articles on the topic 'Aluminium High Pressure Die Casting'

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