Journal articles: 'High pressure die casting'

1

Jelínek, P., and E. Adámková. "Lost Cores for High-Pressure Die Casting." Archives of Foundry Engineering 14, no. 2 (June 1, 2014): 101–4. http://dx.doi.org/10.2478/afe-2014-0045.

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Abstract Development of salt cores prepared by high-pressure squeezing and shooting with inorganic binders has shown a high potential of the given technology even for high-pressure casting of castings. Strength, surface quality of achieved castings, and solubility in water become a decisive criterion. The shape and quality of grain surface particularly of NaCl - cooking salts that can be well applied without anticaking additives has shown to be an important criterion. Thus the salt cores technology can cover increasingly growing demands for casting complexity especially for the automobile industry.

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Semanco, Pavol, Marcel Fedák, Miroslav Rimár, Peter Skok, and Emil Ragan. "Equation Model of the Cooling Process in High Pressure Die-Casting Technology." Advanced Materials Research 505 (April 2012): 165–69. http://dx.doi.org/10.4028/www.scientific.net/amr.505.165.

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In the die-casting technology there is very necessary to determine cooling process of castings in metallic mold especially in the case of castings with great weight to achieve quality surface and properties of the casting without any defects. To regulate cooling in the time course, it is desirable to develop equation of regulation system that determining mold temperature dependence on casting temperature. In the paper we proposed model of regulatory system in the cooling process of casting in a mold that is based on an analysis of amplitude, phase and transition characteristics. The result is presented as proposal for regulatory circuit to control cooling process of casting in the mold.

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Pałyga, Ł., M. Stachowicz, and K. Granat. "Effect of parameters of high-pressure die casting on occurrence of casting nonconformities in sleeves of silumin alloy EN AB 47100." Archives of Metallurgy and Materials 62, no. 1 (March 1, 2017): 373–78. http://dx.doi.org/10.1515/amm-2017-0058.

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Abstract The paper presents a research on the effect of extreme - for the technology of the considered silumin EN AB 47100 - parameters of high-pressure die casting on occurrence of casting nonconformities. Considered was influence of the way of assembling the mould cooled-down to 140-160°C, non-standard for the selected casting, and pouring temperature in the range of 705 to 720°C (higher than the recommended) of non-refined alloy. The castings were prepared with use of a high-pressure casting machine made by Kirov with mould closing force of 2500 kN. Occurrence of nonconformities was evaluated on properly prepared specimens taken from the castings manufactured with various parameters of the injection piston and various multiplication pressures. The results were subjected to quantitative and qualitative analyses of casting nonconformities and distribution of major alloying elements. It was found that proper selection of working parameters of the casting machine, in spite of disadvantageous pouring conditions, makes it possible to reduce occurrence of some casting defects, like shrinkage cavities and porosity, to improve tightness of castings even when the alloy refining process is omitted.

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Molnár, Dániel, Ádám Kiss, and Csaba Majoros. "Casting Issues of Thick-Walled High Pressure Die Castings." International Journal of Engineering and Management Sciences 5, no. 2 (April 15, 2020): 159–66. http://dx.doi.org/10.21791/ijems.2020.2.20.

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Die casting is a manufacturing process for producing accurately dimensioned, sharply defined, smooth or textured surface metal parts. It is accomplished by injecting liquid metal at fast velocity and under high pressure into reusable steel dies. Compared to other casting processes, die casting is at the top end of both velocity and pressure. The high velocity translates into a very turbulent flow condition. The process is often described as the shortest distance between raw material and the finished product. Pre-fill is a process technique that is the result of significantly delaying the start of fast shot beyond the “metal at the gate” position. It can be stated as a percentage of cavity fill or as a distance beyond metal at the gate.

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Łągiewka, M., Z. Konopka, M. Nadolski, and A. Zyska. "The Effect of Vacuum Assistance on the Quality of Castings Produced by High Pressure Die Casting Method." Archives of Foundry Engineering 14, no. 2 (June 1, 2014): 23–26. http://dx.doi.org/10.2478/afe-2014-0030.

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Abstract The presented work is aimed to deal with the influence of changes in the value of negative (relative) pressure maintained in the die cavity of pressure die casting machine on the surface quality of pressure castings. The examinations were held by means of the modified Vertacast pressure die casting machine equipped with a vacuum system. Castings were produced for the parameters selected on the basis of previous experiments, i.e. for the plunger velocity in the second stage of injection at the level of 4 m/s, the pouring temperature of the alloy equal to 640°C, and the die temperature of 150°C. The examinations were carried on for three selected values of negative gauge pressure: - 0.03, - 0.05, and - 0.07 MPa. The quality of casting was evaluated by comparing the results of the surface roughness measurements performed for randomly selected castings. The surface roughness was measured by means of Hommel Tester T1000. After a series of measurements it was found that the smoothest surface is exhibited by castings produced at negative gauge pressure value of - 0.07 MPa.

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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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Gunasegaram, Dayalan R., Michel Givord, and Robert G. O'Donnell. "ATM: A Greener Variant of High Pressure Die Casting." Materials Science Forum 618-619 (April 2009): 27–31. http://dx.doi.org/10.4028/www.scientific.net/msf.618-619.27.

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

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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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Liu, Yixiong, Haiping He, Jixiang Gao, Gang Li, Yi Liang, and Liejun Li. "Research on the low-pressure casting process of a double suction impeller in 304 austenitic stainless steel with high performance and thin-wall complex structure." Journal of Physics: Conference Series 2390, no. 1 (December 1, 2022): 012078. http://dx.doi.org/10.1088/1742-6596/2390/1/012078.

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Abstract The manufacturing of thin-wall complex castings using pressure-assisted casting is one of the most significant challenges for structural applications requiring excellent mechanical properties and fuel. In this paper, efforts have been made to manufacture thin-wall complex structure casting using high-temperature alloys with high strength. Low pressure casting forming process was used to manufacture a double suction impeller in 304 austenitic stainless steel with a thin-wall complex structure. By combining 3D printed sand mold with an optimized low-pressure casting process, a double suction impeller with a thin-wall thickness of 3mm was successfully prepared. The prepared double suction impeller showed structural integrity, smooth surface, and compact structure. The filling and solidification process of the 304 austenitic stainless-steel melts were analyzed using casting simulation software. The casting had an excellent mechanical property with a tensile strength of 595 MPa, yield strength of 265 MPa, and elongation of 48%. Results show that the improved low-pressure casting processes could be applied to the production of thin-wall complex structure parts during high-temperature casting processes. The results are of great significance to the casting of high-temperature alloys.

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Liu, Yan Gai, Zhao Hui Huang, Hao Ding, Ming Hao Fang, and Shou Mei Xiong. "Study on Pressure Variations in the Mold of Magnesium Alloy Die Castings." Key Engineering Materials 353-358 (September 2007): 1614–16. http://dx.doi.org/10.4028/www.scientific.net/kem.353-358.1614.

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High pressure die casting is the most common method in making magnesium alloys for both auto parts and 3C products. Pressure variations in the mold during mold filling and solidification process have direct influences on the quality and properties of die castings. In this paper, a cylinder head cover was produced to experimentally study pressure variations in the mold during magnesium alloy die-casting process in real time for the first time. Pressure varies at different positions in the mold during die casting process. This study indicates that mold filling and solidification process of magnesium alloy die castings can be described by pressure curves obtained by pressure measurement at different test positions in the cavity in real time.

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Dúl, Jenő, Richárd Szabó, and Attila Simcsák. "Effect of Temperature on the Properties of High Pressure Die Casting." Materials Science Forum 649 (May 2010): 473–79. http://dx.doi.org/10.4028/www.scientific.net/msf.649.473.

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Quality of high pressure die castings is influenced by a lot of factors. Among them, the most important ones are the melt-, and die temperatures. This paper shows a data acquisition system, developed for measuring the melt and die temperatures and the results of the temperature measurements obtained under variable conditions. Evaluation of the relationship between the interrelated temperatures and the casting properties is based on analyzing the structure of the castings.

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12

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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Kowalczyk, Wojciech, Rafał Dańko, Marcin Górny, Magdalena Kawalec, and Andriy Burbelko. "Influence of High-Pressure Die Casting Parameters on the Cooling Rate and the Structure of EN-AC 46000 Alloy." Materials 15, no. 16 (August 18, 2022): 5702. http://dx.doi.org/10.3390/ma15165702.

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The paper presents the results of the research on the impact of process parameters of high-pressure, cold-chamber die casting of an industrial casting made of aluminium alloy on the casting properties assessed macroscopically by measuring the casting average density and microscopically through the characteristics of the casting microstructure. The analysis covers the influence of three selected velocity settings of the pressing plunger, which determine the filling time, and three values of the compression pressure setting characteristic of the third phase of the casting process. The cooling and solidification simulations of the casting were performed using the ProCAST software. During the simulation tests, the impact of the filling rate of the alloy into the die cavity on the cooling rate and the alloy solidification path at selected points were determined. The conducted research allowed linking the process parameters with the parameters of the casting structure with different wall thicknesses. Metallographic examinations of the castings were carried out using a light microscopy, SEM, and EDS analysis. The fraction of the phases α(Al), the size of dendritic cells, and the size of silicon particles, in the cross-sections of the castings with wall thickness of 3, 6, and 11 mm, respectively, were determined.

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14

Jeon, Joo Mae, Soo Jo Lee, Kyeong Hwan Choe, and Jeung-Soo Huh. "Gas Pressure Effect on Sand Collapse in Kinetic Zone of Lost-Foam Casting." Advances in Materials Science and Engineering 2020 (April 25, 2020): 1–9. http://dx.doi.org/10.1155/2020/5861017.

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Pressure of the kinetic zone is an essential factor for making defect-free castings in lost-foam casting process. The extremely high pressure causes many problems, such as reducing the melt velocity and inclusion of residual decomposition of the pattern in the castings, and very low pressure causes sand collapse. Therefore, the minimum gas pressure for preventing sand collapse is required. When the minimum gas pressure can be predicted, computer simulation becomes possible. Successful computer simulations can help reduce the number of trials and the lead time while designing new casting products. A preliminary sand experiment was conducted to predict the gas pressure and reduce the number of actual casting experiments. In this preliminary sand experiment, compressed air was used instead of gas in the kinetic zone. A new mathematical equation was proposed from the results of the preliminary sand experiment. The void ratio of the sand effect on the minimum gas pressure was included in the equation. An actual casting experiment was conducted by melting nodular cast iron to verify this equation. In the actual casting experiment, pressure of the kinetic zone in front of the metal tip was directly measured. The results obtained from the preliminary sand experiment and the actual casting experiment validated the equation.

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15

Liu, Zi Kang, Min Luo, Da Quan Li, Long Fei Li, and Jian Feng. "Effects of Process Parameters on Shrinkage Porosity in 357 Semi-Solid Die Casting Parts." Materials Science Forum 993 (May 2020): 166–71. http://dx.doi.org/10.4028/www.scientific.net/msf.993.166.

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The shrinkage porosity that was caused by the insufficient feeding during solidification, was a common defect in the semi-solid die casting process. This defect decreased significantly the mechanical properties of the casting. In order to avoid the shrinkage porosity in casting, the die design, slug preparation and die casting process were carefully considered. In this study, a designed mold was used to make the sequential solidification of the slug. The process parameters, including intensification pressure, die temperature and biscuit thickness of the casting, were studied to show their influence on shrinkage porosity defects. The experimental results show that the high intensification pressure, high die temperature and long biscuit can be beneficial to obtain castings with no shrinkage porosity.

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Boroń, Kinga. "Evaluation of porosity of AlZn5Mg castings made by squeeze casting technology." Acta Innovations, no. 32 (July 1, 2019): 12–19. http://dx.doi.org/10.32933/actainnovations.32.2.

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The paper shows the results of research aimed to assess the impact of high squeeze pressure on the porosity of AlZn5Mg alloy castings, including its distribution in slab-type castings with dimensions of 25 x 100 x 200 mm. The research was carried out on castings made by two methods: squeeze casting and gravity casting. The pressing was conducted at a pressure of 100 MPa at an initial mould temperature of 200°C. The research identified the middle and outer parts of the casting. Experimental research was preceded by numerical simulation of the casting solidification, then a porosity assessment was carried out using the hydrostatic weighing method, which was supplemented by structural observations. The results of the research showed a two-fold decrease in the porosity in the middle part of the casting which is most exposed to the occurrence of shrinkage voids formed in the final clotting phase. Structural tests revealed the occurrence of dispersed porosity in castings, mainly of shrinkage and / or shrinkage-gas origin. The impact of pressure of 100 MPa during solidification caused fragmentation of the primary structure of castings, which resulted in a higher grain density.

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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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Ignaszak, Zenon, and Jakub Hajkowski. "Gas- and Shrinkage Porosities in Al-Si High-Pressure Die-Castings - Virtualization and Experimental Validation." Defect and Diffusion Forum 364 (June 2015): 80–91. http://dx.doi.org/10.4028/www.scientific.net/ddf.364.80.

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The porosity (void caused by technological reasons) in engineering materials always decrease their mechanical characteristics and usually affects the deterioration of the functional mechanical characteristics of the finished products. In the castings the porosity resulting from the specific casting processes phenomena occurs inevitably in the matrix structure. The paper shows this problem in relation to the High-Pressure-Die-Casting (HPDC) technology of Al-Si alloy. The analysis of the experimental results and the results from virtualization of HPDC process allowed to assess the effectiveness of this mixed scenario and improve the quality predictions probability for HPDC, with particular consideration of shrinkage and gas porosities. The problem of the tolerance (admissibility) of porosity occurrence in castings and the castings made of liquid Al-Si alloy to which the gas (hydrogen) was introduced intentionally are signalized.

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Zyska, A., Z. Konopka, M. Łągiewka, and M. Nadolski. "Porosity of Castings Produced by the Vacuum Assisted Pressure Die Casting Method." Archives of Foundry Engineering 15, no. 1 (March 1, 2015): 125–30. http://dx.doi.org/10.1515/afe-2015-0023.

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Abstract The paper presents the results of investigations concerning the influence of negative (relative) pressure in the die cavity of high pressure die casting machine on the porosity of castings made of AlSi9Cu3 alloy. Examinations were carried out for the VertaCast cold chamber vertical pressure die casting machine equipped with a vacuum system. Experiments were performed for three values of the applied gauge pressure: -0.3 bar, -0.5 bar, and -0.7 bar, at constant values of other technological parameters, selected during the formerly carried initial experiments. Porosity of castings was assessed on the basis of microstructure observation and the density measurements performed by the method of hydrostatic weighing. The performed investigation allowed to find out that - for the examined pressure range - the porosity of castings decreases linearly with an increase in the absolute value of negative pressure applied to the die cavity. The negative pressure value of -0.7 bar allows to produce castings exhibiting porosity value less than 1%. Large blowholes arisen probably by occlusion of gaseous phase during the injection of metal into the die cavity, were found in castings produced at the negative pressure value of -0.3 bar. These blowholes are placed mostly in regions of local thermal centres and often accompanied by the discontinuities in the form of interdendritic shrinkage micro-porosity. It was concluded that the high quality AlSi9Cu3 alloy castings able to work in elevated temperatures can be achieved for the absolute value of the negative pressure applied to the die cavity greater than 0.5 bar at the applied set of other parameters of pressure die casting machine work.

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Podprocká, Radka, Jozef Malik, and Dana Bolibruchová. "Defects in High Pressure Die Casting Process." Manufacturing Technology 15, no. 4 (September 1, 2015): 674–78. http://dx.doi.org/10.21062/ujep/x.2015/a/1213-2489/mt/15/4/674.

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Hey, A. W., A. Bresciani, L. A. Correia, Rodrigo Moreno, and Arturo Salomoni. "Industrial Pressure Casting of High Alumina Ceramics." Key Engineering Materials 132-136 (April 1997): 350–53. http://dx.doi.org/10.4028/www.scientific.net/kem.132-136.350.

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Otarawanna, S., C. M. Gourlay, H. I. Laukli, and A. K. Dahle. "Microstructure formation in high pressure die casting." Transactions of the Indian Institute of Metals 62, no. 4-5 (October 2009): 499–503. http://dx.doi.org/10.1007/s12666-009-0081-2.

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Molnár, Dániel, Jenő Dúl, and Richárd Szabó. "Simulation of High Pressure Die Casting Solidification." Materials Science Forum 508 (March 2006): 555–60. http://dx.doi.org/10.4028/www.scientific.net/msf.508.555.

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By the help of simulation software it is possible to follow and predict the high pressure die casting process. In the Department of Foundry Engineering at the University of Miskolc, Hungary we use both Finite Element- and Finite Difference programs for simulation. In this paper we examine a special specimen, a plate with knobs, witch has point symmetric hot spots and cored parts which effect the characteristic of flow and solidification. We examined the solidification process and the temperature distribution. We determined that the finite element method, because of the meshing and the calculation mode, is more suitable for the simulation of thermal processes.

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Bonollo, Franco, Nicola Gramegna, and Giulio Timelli. "High-Pressure Die-Casting: Contradictions and Challenges." JOM 67, no. 5 (February 27, 2015): 901–8. http://dx.doi.org/10.1007/s11837-015-1333-8.

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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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Szalva, Péter, and Imre Norbert Orbulov. "Influence of Vacuum Support on the Fatigue Life of AlSi9Cu3(Fe) Aluminum Alloy Die Castings." Journal of Materials Engineering and Performance 29, no. 9 (August 27, 2020): 5685–95. http://dx.doi.org/10.1007/s11665-020-05050-y.

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Abstract High-pressure die casting (HPDC) is a near-net-shape process that produces high quality castings with narrow dimensional tolerances. The HPDC castings are being increasingly used due to good flexibility and high productivity, especially for the automotive industry. Depending on the location of the cast components, there are ever more complex geometries and increasing strength requirements that can be achieved by the application of vacuum-assisted die casting (VPDC). The most specific features of the HPDC process are the rapid mold filling, high cooling rate and intensification pressure. As a consequence of these highlighted features, the process generally leads to the formation of casting defects, such as gas porosity, shrinkage, and entrapped oxide films. However, the VPDC casting process is capable to significantly reduce the amount of these casting defects. The aim of this work is to compare the HPDC and VPDC castings’ high-cycle fatigue behavior and to describe how the casting defects affect the fatigue failure. Before the fatigue tests, the samples were investigated with non-destructive (NDT) materials testing methods such as hydrostatic weighing, x-ray, and computer tomography (CT) to characterize the gas pore and shrinkage pore populations of the material. The AlSi9Cu3(Fe) aluminum alloy castings have been subjected to constant amplitude load by uniaxial fatigue tests in the high-cycle fatigue region with a stress asymmetry ratios of R = −1 and R = 0.1. The resulting fracture surfaces are analyzed through light optical microscopy (LOM) and scanning electron microscopy (SEM). VPDC increased the number of cycles to fracture and decreased the scatter at the given load levels compared to conventional HPDC casting. Moreover, VPDC significantly decreased the porosity size and volume, and the occurrence of oxide flakes is also decreased, resulting in the improvement in the number of cycle to failure.

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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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Yang, Xiang Jie, Yi He, Yong Bo Zhu, Chuan Lin Hu, Hong Min Guo, Yun Hai Jing, and Guang Bin Yi. "The Study of A356 Alloy Rheo-Squeeze Casting Process." Solid State Phenomena 256 (September 2016): 270–75. http://dx.doi.org/10.4028/www.scientific.net/ssp.256.270.

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In this paper, the castings of A356 alloy were made by the rheo-squeeze casting with slurry-making from the process of LSPSF. Experiments were designed to study the influence of three parameters in rheo-squeeze casting process, such as injection speed, mould preheating temperature and injection pressure, on castings performance. The results show that high-quality castings were produced with the injection speed of 0.5m/s ,the mould preheating temperature of 240°C, the injection pressure of 50MPa. The mechanical properties, such as the yield strength, tensile strength and elongation of the castings with T6 heat treatment are 241 MPa, 328MPa and 11.6%, respectively.

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Jarfors, Anders E. W., Ruslan Sevastopol, Karamchedu Seshendra, Qing Zhang, Jacob Steggo, and Roland Stolt. "On the Use of Conformal Cooling in High-Pressure Die-Casting and Semisolid Casting." Technologies 9, no. 2 (May 21, 2021): 39. http://dx.doi.org/10.3390/technologies9020039.

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Today, tool life in high pressure die casting (HPDC) is of growing interest. A common agreement is that die life is primarily decided by the thermal load and temperature gradients in the die materials. Conformal cooling with the growth of additive manufacturing has raised interest as a means of extending die life. In the current paper, conformal cooling channels’ performance and effect on the thermal cycle in high-pressure die casting and rheocasting are investigated for conventional HPDC and semisolid processing. It was found that conformal cooling aids die temperature reduction, and the use of die spray may be reduced and support the die-life extension. For the die filling, the increased temperature was possibly counterproductive. Instead, it was found that the main focus for conformal cooling should be focused to manage temperature around the in-let bushing and possibly the runner system. Due to the possible higher inlet pressures for semisolid casting, particular benefits could be seen.

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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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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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Mao, Hong Kui, Bin Ye Yao, and Hong Xu. "Casting Filling Simulation Technology Based on Component Wise Splitting Method." Applied Mechanics and Materials 395-396 (September 2013): 1199–205. http://dx.doi.org/10.4028/www.scientific.net/amm.395-396.1199.

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The casting filling numerical simulation technology is of great significance to optimize the casting process, improve castings quality, and reduce production costs. Component wise splitting method only uses a small amount of iterations between velocity field and pressure field, so it has high computational efficiency in theory. The calculation accuracy is analyzed through Lid-driven cavity flow model, the result has a good agreement with literature results in low Reynolds number, but there is a big deviation when high Reynolds number. Finally the fraction step method is applied to the solution of the low pressure casting filling process, Calculation results coincided with the experimental results.

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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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Bubenkó, Marianna, and Dániel Molnár. "Simulation Aspects of the High Pressure Die Casting Process." International Journal of Engineering and Management Sciences 4, no. 1 (March 3, 2019): 521–29. http://dx.doi.org/10.21791/ijems.2019.1.64.

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

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Sadayappan, K., W. Kasprzak, Zach Brown, L. Quimet, and Alan A. Luo. "Characterization of Magnesium Automotive Components Produced by Super-Vacuum Die Casting Process." Materials Science Forum 618-619 (April 2009): 381–86. http://dx.doi.org/10.4028/www.scientific.net/msf.618-619.381.

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

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Puspitasari, P., and J. W. Dika. "Casting Quality Enhancement Using New Binders on Sand Casting and High-Pressure Rheo-Die Casting." Uspehi Fiziki Metallov 20, no. 3 (August 30, 2019): 396–425. http://dx.doi.org/10.15407/ufm.20.03.396.

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Cheng, Le, Hong Xing Lu, Qiang Zhu, Xiang Kai Zhang, Ai Di Shen, and Peng Yang. "Evolution of Microstructure and Mechanical Properties of Semi-Solid Squeeze Cast A356.2 Aluminum Alloy during Heat Treatment." Solid State Phenomena 285 (January 2019): 139–45. http://dx.doi.org/10.4028/www.scientific.net/ssp.285.139.

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Semi-solid squeeze casting (SS-SC) is a new processing technology which combines semi-solid processing (SSP) and squeeze casting (SC). In this process, semi-solid slurry fills mold by using its rheological property and solidifies under high pressure. It has several advantages, such as stable filling, small heat impact to the mold, low cost, high density and excellent mechanical properties of castings, which receives more and more attention. The microstructure of castings provided by SS-SC is quite different from that of casting provided by conventional SC in as-cast condition, which leads to differences in the evolution of microstructure and mechanical properties in heat treatment process. In this study, A356.2 aluminum alloys castings were provided by both SS-SC and conventional SC respectively. The evolution of microstructure and mechanical properties of castings during heat treatment was investigated to obtain the best mechanical properties of semi-solid squeeze castings. Keywords:Microstructure, Mechanical properties, Heat treatment, A356 alloy, Semi-Solid Squeeze Casting

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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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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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Zeng, Jian Min, and Yao He Zhou. "A New Sand Casting Process with Accelerated Solidification Rate." Materials Science Forum 686 (June 2011): 765–69. http://dx.doi.org/10.4028/www.scientific.net/msf.686.765.

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In order to solve the problems involved in coarse grains, macro and micro porosities initiated by low solidification rate in sand casting, an innovative counter-gravity sand casting process, Casing under Adjustable Pressure with Accelerated Solidification (CAPAS) was put forward in this paper. The hydrodynamics of mold filling for CAPAS is based on Bernoulli's principle. The mold and crucible were placed separately in the upper and lower chambers, with the feed tube connected between them. High-speed jet flow of air made negative pressure in the upper chamber. In this way, pressure differential was created between the two chambers. Thereby the molten metal in the crucible was forced to flow upward smoothly to fill the mold cavity. After mold filling, cold air was introduced into sand mold through aisles that are set within the mold, which results in strong convective heat exchange at the casting/mold interface. So solidification rate of casting increased dramatically. The microstructures of the aluminum castings were compared between CAP (Low pressure sand casting) and CAPAS by optical microscope. The results showed that the microstructure of CAPAS aluminum casting was much finer than that of CAP casting and tensile strength markedly increased.

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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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Ignaszak, Z., and J. Hajkowski. "Contribution to the Identification of Porosity Type in AlSiCu High-Pressure-Die-Castings by Experimental and Virtual Way." Archives of Foundry Engineering 15, no. 1 (March 1, 2015): 143–51. http://dx.doi.org/10.1515/afe-2015-0026.

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Abstract The paper concerns the problem of discontinuity in high pressure die castings (HPDC). The compactness of their structure is not perfect, as it is sometimes believed. The discontinuities present in these castings are the porosity as follow: shrinkage and gas (hydrogen and gas-air occlusions) origin. The mixed gas and shrinkage nature of porosity makes it difficult to identify and indicate the dominant source. The selected parameters of metallurgical quality of AlSi9Cu3 alloy before and after refining and the gravity castings samples (as DI - density index method), were tested and evaluated. This alloy was served to cast the test casting by HPDC method. The penetrating testing (PT) and metallographic study of both kinds of castings were realized. The application of the NF&S simulation system allowed virtually to indicate the porosity zones at risk of a particular type in gravity and high-pressure-die-castings. The comparing of these results with the experiment allowed to conclude about NF&S models validation. The validity of hypotheses concerning the mechanisms of formation and development of porosity in HPDC casting were also analyzed.

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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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Jia, Zhi Xin, Ning Bo Hu, Ji Qiang Li, Li Jun Liu, and Li Qiong Chen. "Die-Casting Die Design Based on the Application of CAE Simulation." Applied Mechanics and Materials 201-202 (October 2012): 541–44. http://dx.doi.org/10.4028/www.scientific.net/amm.201-202.541.

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High pressure die casting is a high volume component manufacturing process which is used extensively in many aspects. There are many factors affecting the quality of die-casting die. In this paper, the CAE simulations of filling and solidification processes for die-casting are studied. Numerical analyses are presented for two practical die-casting parts using HZ CAE software. The temperature distributions and filling states in solidification and filling process are presented. Then the deficiencies of the part are predicted. Based on the analyzing results, the structures of the two dies are optimized and longer die service life and high-quality castings are obtained. It is proved that CAE simulation results can offer a helpful reference for die-casting die design.

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Eperješi, Š., M. Matvija, ľ. Eperješi, and M. Vojtko. "Evaluation of Cracking Causes of AlSi5Cu3 Alloy Castings." Archives of Metallurgy and Materials 59, no. 3 (October 28, 2014): 1089–92. http://dx.doi.org/10.2478/amm-2014-0187.

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Abstract Recently, the castings made from aluminum-silicon alloys by pressure die casting are increasingly used in the automotive industry. In practice, on these castings are high demands, mainly demands on quality of their structure, operating life and safety ensuring of their utilization. The AlSi5Cu3 alloy castings are widely used for production of car components. After the prescribed tests, the cracks and low mechanical properties have been identified for several castings of this alloy, which were produced by low pressure casting into a metal mould and subsequent they were heat treated. Therefore, analyses of the castings were realized to determine the causes of these defects. Evaluation of structure of the AlSi5Cu3 alloy and causes of failure were the subjects of investigation presented in this article.

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Battaglia, Eleonora, Franco Bonollo, Elena Fiorese, and Giorgio Kral. "Overview of the Correlations between Process Parameters, Microstructure and Mechanical Properties of Reference Castings and Industrial Demonstrators." Key Engineering Materials 710 (September 2016): 35–40. http://dx.doi.org/10.4028/www.scientific.net/kem.710.35.

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Among the Aluminum casting processes, High Pressure Die Casting (HPDC) is an efficient, versatile and economic way for producing large number of components. Nevertheless, because of the elevated amount of rejected castings, it is important to know which are the main causes of defect formation and their effects on microstructure and mechanical properties. This paper presents, within the European MUSIC project, an overview of the preliminary correlations obtained studying both castings with defect generator geometry, referred to as Horse-shoe Reference Castings, and industrial demonstrators, referred to as Gear Box Housing. The deduced correlations between static mechanical properties and casting defects highlighted interesting trends in both cases.

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Tatiana Lysenko, Yuriy Morozov, Kyryll Kreitser, and Evgeny Kozishkurt. "USING THE SPH METHOD FOR MODELING THE CRYSTALLIZATION PROCESS OF ALUMINUM ALLOYS." World Science 1, no. 3(55) (March 31, 2020): 26–33. http://dx.doi.org/10.31435/rsglobal_ws/31032020/6981.

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The purpose of the study was to obtain castings with increased mechanical properties by low-pressure casting using excess pressure on the crystallized casting. The simulation of the process of filling and crystallization of prototypes using the SPH method was carried out. The studies were carried out on a modernized low-pressure injection molding machine model U8261. Prototypes were obtained from AK7ch alloy, special attention is paid to interfacial interaction and intensification of the heat transfer process due to the application of excess pressure. Based on the data obtained, it was found that during crystallization under excessive pressure there is a supercooling effect that reduces the casting solidification time. The use of the SPH method for modeling foundry processes has shown a high level of reliability and requires further development.

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Sharma, Bharat. "BLOW HOLE CONTROL IN HIGH PRESSURE DIE CASTING." International Journal of Engineering Applied Sciences and Technology 5, no. 7 (November 1, 2020): 140–44. http://dx.doi.org/10.33564/ijeast.2020.v05i07.022.

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Cleary, Paul W., and Joseph Ha. "Three dimensional modelling of high pressure die casting." International Journal of Cast Metals Research 12, no. 6 (May 2000): 357–65. http://dx.doi.org/10.1080/13640461.2000.11819373.

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Birch, J. M. "High pressure die casting of non-ferrous alloys." Materials Science and Technology 4, no. 3 (March 1988): 218–21. http://dx.doi.org/10.1179/mst.1988.4.3.218.

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Journal articles on the topic 'High pressure die casting'

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