Search

Fluidity tests of 99.9%Al and 99.7%Al were conducted using a die casting machine equipped with a spiral die with a channel gap of 0.5 mm. The effects of die temperature and plunger speed on the fluidity were investigated. To clarify the flow length for these alloys, ADC12 and Al-X%Fe (X ≤ 1.1) were also cast. A 1.0 mm channel gap was also used to compare the fluidity in a wider gap. The fluidity of 99.9%Al and 99.7%Al at a die temperature of 30 °C and a plunger speed of 0.2 m/s was superior to that at 150 °C and 0.8 m/s when the channel gap was 0.5 mm, and similar results were found for ADC12 and Al-X%Fe. When the die temperature was 30 °C, the fluidity of 99.9%Al and 99.7%Al decreased as the plunger speed increased when the channel gap was 0.5 mm, and similar results were also found for ADC12 and Al-X%Fe. These results did not align with conventional expectations. A discussion of the results based on the peeling and re-melting of the solidified layer was provided. [ABSTRACT FROM AUTHOR]

The die-casting process of ADC12 aluminum alloy right crankcase cover was simulated based on AnyCasting software, and the influence of pouring temperature, initial mold temperature and injection speed on the filling and solidification process of ADC12 right crankcase cover casting was explored by orthogonal experiment method. The optimal process parameters were obtained through optimization, and the die-casting mold was designed. The program was verified in production. The results show that the porosity and shrinkage of the right crankcase cover are mainly concentrated in the thick wall part. The sequence of process parameters that affect the residual melt modulus is pouring temperature, initial mold temperature, and injection speed; The best combination of process parameters: pouring temperature is ∼680 °C, initial mold temperature is ∼200 °C, injection speed is ∼5 m/s. By analyzing the filling process and temperature field simulation results, the casting structure, mold structure and cooling system were optimized, and the process plan was improved. The production verification was carried out according to the optimized process plan. The casting quality is good and has no obvious defects, which meets the actual production needs.

In order to effectively reduce energy consumption and increase range mile, new energy vehicles represented by Tesla have greatly aroused the application of integrated magnesium (Mg) alloy die casting technology in automobiles. Previously, the application of Mg alloys in automobiles, especially in automotive cockpit components, is quite extensive, while it has almost disappeared for a period of time due to its relatively high cost, causing a certain degree of information loss in the application technology of Mg alloy parts in automobiles. The rapid development of automotive technology has led to a higher requirement for the automotive components compared with those traditional one. Therefore, whatever the components themselves, or the Mg alloy materials and die casting process have to face an increasing challenge, needing to be upgraded. In addition, owing to its high integration characteristics, the application of Mg alloy die casting technology in large-sized and thin-walled automotive parts has inherent advantages and needs to be expanded urgently. Indeed, it necessitates exploring advance Mg alloys and new product structures and optimizing die casting processes. This article summarizes and analyzes the development status of thin-walled and large-sized die casting Mg alloy parts in passenger car cockpit and corresponding material selection methods, die casting processes as well as mold design techniques. Furthermore, this work will aid researchers in establishing a comprehensive understanding of the manufacture of thin-walled and large-sized die casting Mg alloy parts in automobile cockpit. It will also assist them in developing new Mg alloys with improved comprehensive performance and new processes to meet the high requirements for die casting automotive components. [ABSTRACT FROM AUTHOR]

Copyright of FME Transactions is the property of University of Belgrade, Faculty of Mechanical Engineering and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

This study systematically analyzed the effect of design conditions on filling behavior and product characteristics when forming thin plates of magnesium alloy (AZ91D) of 0.5 mm or less using the die casting method. As a research method, a casting analysis simulation program was used to predict filling and solidification behavior under various process conditions. The molten metal injection temperature (610~670 °C), mold temperature (160~220 °C), and cooling water temperature (10~55 °C) were selected as key variables, and an analysis was performed for a total of five conditions. A simulation was conducted to analyze the charging speed distribution, location of oxides and bubbles, and solidification pattern. As a result of the study, the flow of molten metal in the low and high-speed sections of the plunger, uniformity of product thickness, and supply conditions of the molten metal were confirmed to be major factors. It is important to manage the molten metal injection temperature at an appropriate level to minimize product defects. Based on these conditions, a prototype was manufactured, the microstructure was observed, and a fine and uniform grain structure was observed in most areas. In mechanical property evaluation, superior physical properties were secured compared to existing bulk materials. [ABSTRACT FROM AUTHOR]

Against the backdrop of climate policy goals and the EU's aim for a resource-efficient economy, the foundry industry must rethink product range, energy consumption, and production technologies. Light metal casting, which is performed through processes like gravity die casting and high-pressure die casting, requires effective thermal management, which is crucial for optimising mould filling, solidification, cycle times, and part quality. Against this background, this study presents the development and characterisation of a cooling system that completely dispenses with energy-intensive heating/cooling devices. The system is based on a mask shape combined with internal spray cooling. This paper shows the simulation workflow for developing the mould mask and the design of the cooling system and compares the performance with conventional temperature control using channels. In the tests, an 82% higher cooling rate was achieved with Cool-Spray than with conventional temperature control, which was approx. 2.5 mm below the cavity surface. In addition to the more dynamic temperature control, the potential for process control was utilised, and the component quality of the test part was significantly improved compared to conventional temperature control. [ABSTRACT FROM AUTHOR]

Die casting has many advantages, such as high precision, mass production, and excellent recyclability. However, gas defects in the product have become a problem. One countermeasure to this problem is to design the injection input of the plunger appropriately. Recently, CFD has been used to design plunger injection inputs, and by combining with optimization techniques, auto-design of plunger injection inputs has been possible. However, CFD is difficult to apply because of the high cost of CFD resources, the need to resource IT engineers, and the time required for its auto-design. Therefore, we propose a new injection input design method based on an algebraic approach, enabling anyone to design a plunger injection input that prevents gas defects with ease and at a low cost. Simulation and experimental results verified the effectiveness of the proposed method. [ABSTRACT FROM AUTHOR]

The demand for lightweight and cost-effective heat sinks is increasing. A typical method for economically manufacturing complex-shape heat sinks is die casting. To reduce the weight of the die-cast heat sinks, thinning the fins and base is common practice. We experimented with casting heat sinks using Al-25%Si in a conventional die casting machine with the aim of economically producing thinner fins and bases. Compared with the aluminum alloy used in conventional die casting, Al-25%Si has superior fluidity, which is proven to be very useful for reducing the thickness of the fins and base. As a result, we successfully reduced the heat sink weight using Al-25%Si and a conventional die casting machine. To investigate the properties of the produced Al-25%Si thin fin heat sink, we compared the effects of fin thickness, fin height, number of fins, and base thickness on heat dissipation and weight reduction. Additionally, we compared the weight and heat dissipation properties with those of a commercial heat sink and found that our Al-25%Si heat sink maintains the same heat dissipation performance but for 35% lower weight. [ABSTRACT FROM AUTHOR]

Purpose: This study aims to elucidate the machining properties of low-cost expanded clay-reinforced syntactic foams by using different neural network models for the first time in the literature. The main goal of this endeavor is to create a casting machining-neural network modeling flow-line for real-time foam manufacturing in the industry. Design/methodology/approach: Samples were manufactured via an industry-based die-casting technology. For the slot milling tests performed with different cutting speeds, depth of cut and lubrication conditions, a 3-axis computer numerical control (CNC) machine was used and the force data were collected through a digital dynamometer. These signals were used as input parameters in neural network modelings. Findings: Among the algorithms, the scaled-conjugated-gradient (SCG) methodology was the weakest average results, whereas the Levenberg–Marquard (LM) approach was highly successful in foreseeing the cutting forces. As for the input variables, an increase in the depth of cut entailed the cutting forces, and this circumstance was more obvious at the higher cutting speeds. Research limitations/implications: The effect of milling parameters on the cutting forces of low-cost clay-filled metallic syntactics was examined, and the correct detection of these impacts is considerably prominent in this paper. On the other side, tool life and wear analyses can be studied in future investigations. Practical implications: It was indicated that the milling forces of the clay-added AA7075 syntactic foams, depending on the cutting parameters, can be anticipated through artificial neural network modeling. Social implications: It is hoped that analyzing the influence of the cutting parameters using neural network models on the slot milling forces of metallic syntactic foams (MSFs) will be notably useful for research and development (R&D) researchers and design engineers. Originality/value: This work is the first investigation that focuses on the estimation of slot milling forces of the expanded clay-added AA7075 syntactic foams by using different artificial neural network modeling approaches. [ABSTRACT FROM AUTHOR]

Conventional cooling channels used in die casting molds exhibit significant drawbacks, resulting in extended cooling times for cast parts. Issues such as the formation of dirt, limescale, and corrosion substantially diminish the thermal efficiency of these channels, leading to challenges in achieving uniform cooling and potential quality issues. In response to these challenges, this study proposes Topology Optimization as a novel approach. It involves designing cooling structures through Topology Optimization to replace traditional cooling channels, incorporating both Discrete and Gaussian boundary conditions to optimize thermal efficiency. Additionally, Structural Topology Optimization is employed to ensure structural integrity, preventing deformation or yielding under high loads during the die casting process. Numerical analysis revealed superior thermal performance compared to conventional channels, particularly when subjected to Discrete and Gaussian boundary conditions. Furthermore, the application of the latter establishes conformal cooling and minimizes temperature gradients in the casting, reducing casting defects such as shrinkage porosity. These findings highlight the efficacy of Topology Optimization in addressing the challenges of traditional cooling methods, with wide-ranging implications for manufacturing processes utilizing permanent molds for shaping materials. [ABSTRACT FROM AUTHOR]

This study investigates various processing approaches, interface characteristics, and mechanical properties of an aluminum (Al) matrix composite reinforced with additively manufactured (AM) 316L stainless-steel (SS) lattice. The AM-316L-SS lattice, boasting a 30 % infill density, was fabricated using the laser powder bed fusion technique. The Al-matrix was integrated with the AM-316L-SS reinforcement through experimentation involving pre-stirring of the molten Al under pressurized and unpressurized die-casting conditions. A well-bonded interface, with cohesive regions, was obtained in the pre-stirred structures. In contrast, regions of decohesion were displayed in cast structures without pre-stirring, leading to the presence of pores and the manifestation of imperfect bond interfaces. Compression tests conducted on the sound composite demonstrated enhanced mechanical properties, with a compressive strength of approximately 163 MPa, significantly higher than that of the pure Al-matrix (approximately 80 MPa). Localized interface cracking was initiated by stress gradients and plastic deformation, leading to microcrack propagation into the Al-matrix.

Fluidity tests of 99.9%Al and 99.7%Al were conducted using a die casting machine equipped with a spiral die with a channel gap of 0.5 mm. The effects of die temperature and plunger speed on the fluidity were investigated. To clarify the flow length for these alloys, ADC12 and Al-X%Fe (X ≤ 1.1) were also cast. A 1.0 mm channel gap was also used to compare the fluidity in a wider gap. The fluidity of 99.9%Al and 99.7%Al at a die temperature of 30 °C and a plunger speed of 0.2 m/s was superior to that at 150 °C and 0.8 m/s when the channel gap was 0.5 mm, and similar results were found for ADC12 and Al-X%Fe. When the die temperature was 30 °C, the fluidity of 99.9%Al and 99.7%Al decreased as the plunger speed increased when the channel gap was 0.5 mm, and similar results were also found for ADC12 and Al-X%Fe. These results did not align with conventional expectations. A discussion of the results based on the peeling and re-melting of the solidified layer was provided.

Using 3D scanning, coordinate measuring machine, and roughness measurements we evaluated and compared zinc alloy castings produced in conventionally and additively manufactured shaped mould parts. Tests were conducted on castings from new shaped parts and subsequently after approximately every 100,000 shots. Castings from conventional parts had higher dimensional stability, but both types showed decreasing dimensional deviations over time. Castings from new additively manufactured parts had higher roughness initially, but this improved with use. Overall, there were no significant issues, and the benefits of additive-shaped parts prevailed. However, more testing is needed for a final recommendation for use in real operating conditions, requiring hundreds of thousands more shots. [ABSTRACT FROM AUTHOR]

The die casting industry plays a vital role in the manufacturing sector and imagining our life without die casting sector is now next to impossible. In the last 2 decades, one more such technology is revolutionizing manufacturing and prototyping, that is 3D printing. 3D printing is much easier and involves fewer processes in comparison to die casting. This can make it a potential alternative to die casting in the future. Die casting and 3D printing, both in their own way, are unique and have different use cases. It is important to see what both of these technologies will look like in future and how they will revolutionize the manufacturing sector. Feasibility, Industry size, productivity and accuracy of both of these processes will also play a very important role in influencing the market. This paper compares both the technologies with help of a case study of producing 100000 “Frying pans” using both of them and analyzes Feasibility, Industry size, productivity and accuracy to prove monopolized supremacy of die casting over 3D printing. There are various ways in which 3D printing can evolve as a competition to Die casting industry. This paper at the end suggests some solutions to counter the challenges faced by 3D printing technology in order to evolve in Indian Markets. [ABSTRACT FROM AUTHOR]

Silicon carbide (SiC) preform reinforced magnesium (Mg) matrix composites were fabricated by the infiltration of matrix material into a SiC ceramic preform by a cold chamber high-pressure die casting (HPDC) process. All steps of the composite fabrication process are explained, and surface characterizations related to the wear properties of fabricated materials were realized. Wear tests were conducted using a ball-on-disc wear testing device at room temperature under dry sliding conditions. Specific wear rates were calculated using the disk wear loss, which was determined by measuring the wear track width. Wear surfaces were examined using scanning electron microscopy (SEM) equipped with energy-dispersive X-ray spectroscopy (EDS). The results show us that the wear resistance of composites improved and that the most effective wear mechanism is scuffing, which is a type of abrasive wear. In addition, a remarkable increase in surface properties was confirmed using hardness measurements and atomic force microscopy (AFM) investigations. [ABSTRACT FROM AUTHOR]

Non-heat-treated Al–Mg-based die casting alloys have been developed for the structural parts of automobiles. In previous studies, alloy compositions with at least 1.0%Si have been proposed to reduce the hot tearing susceptibility (HTS). On the other hand, the increase in the Si content reduces the ductility. For some automotive body structures, Al–Mg alloy die castings with Si content exceeding 1.0% should not have the required ductility. This study aims to develop an Al–Mg alloy with both high ductility and low HTS by investigating the following three characteristics of an Al–4.5Mg–1.0Mn alloy with 0.2%Si added: (1) additional elements to reduce the HTS, (2) the associated mechanical properties (requirements for the automotive company: 0.2% proof stress ≥ 140 MPa and fracture elongation ≥ 15%), and (3) the mechanism of decreasing the HTS. It was revealed that the co-addition of 0.025%Sr, 0.08%Ti, and 0.016%B reduced the HTS when the hydrogen content of the melt was 0.5–1.0 mL/100 g Al. Furthermore, the 0.2% proof stress and fracture elongation of a lower link arm produced via HPDC with the above composition were found to achieve the requirements. It was also indicated that the mechanism of decrease in the HTS by the Sr addition should result from the decrease in the thermal tensile load due to the formation of hydrogen porosity at a lower solid fraction than that without Sr. It is suggested that when 0.025%Sr, 0.08%Ti, and 0.016%B are added to the Al–4.5Mg–1.0Mn–0.2Si alloy, non-heat-treated automotive structural parts with both high ductility and low HTS will be obtained by high-pressure die casting. [ABSTRACT FROM AUTHOR]

In today's manufacturing industries, hard competition between rival firms makes it compulsory for researchers to design lighter and cheaper machine components due to the megatrends of cost-effectiveness and anti-pollution. At this point, aluminum syntactic foams (ASFs) are new-generation engineering composites and come into the upfront as a problem-solver. Owing to their features like low density, sufficient elongation, and perfect energy absorption ability, these advanced foams have been considerably seductive for many industrial sectors nowadays. In this study, an industrial-oriented automatic die casting technology was used for the first time to manufacture the combination of AA7075/porous expanded clay (PEC). Micro evaluations (optical and FESEM) reveal that there is a homogenous particle distribution in the foam samples, and inspections are compatible with the other ASF studies. Additionally, T6 aging heat treatment was operated on one half of the produced foams to explore the probable impact of aging on the compressive responses. Attained results show that PEC particles can be an alternative to expensive hollow spheres used in the previous works. Besides, a favorable relationship is ascertained between the aging treatment and mechanical properties such as compression strength and plateau strength. [ABSTRACT FROM AUTHOR]

The structural characteristics of the car shift tower cover were analyzed, and the pouring system and overflow system were designed according to the empirical formula.The numerical simulation based on Anycasting software shows that the metal liquid flow and solidification rate of the initial process are not smooth.According to the simulation results, the shape of the runner and the number of the gate were modified, and the point cold water pipe was set at the position where the defects might occur to optimize the process.The numerical simulation of the optimized process scheme shows that the filling process is stable and there is no liquid spatter, and good quality die casting is obtained through actual production.

Against the backdrop of climate policy goals and the EU’s aim for a resource-efficient economy, the foundry industry must rethink product range, energy consumption, and production technologies. Light metal casting, which is performed through processes like gravity die casting and high-pressure die casting, requires effective thermal management, which is crucial for optimising mould filling, solidification, cycle times, and part quality. Against this background, this study presents the development and characterisation of a cooling system that completely dispenses with energy-intensive heating/cooling devices. The system is based on a mask shape combined with internal spray cooling. This paper shows the simulation workflow for developing the mould mask and the design of the cooling system and compares the performance with conventional temperature control using channels. In the tests, an 82% higher cooling rate was achieved with Cool-Spray than with conventional temperature control, which was approx. 2.5 mm below the cavity surface. In addition to the more dynamic temperature control, the potential for process control was utilised, and the component quality of the test part was significantly improved compared to conventional temperature control.

This study systematically analyzed the effect of design conditions on filling behavior and product characteristics when forming thin plates of magnesium alloy (AZ91D) of 0.5 mm or less using the die casting method. As a research method, a casting analysis simulation program was used to predict filling and solidification behavior under various process conditions. The molten metal injection temperature (610~670 °C), mold temperature (160~220 °C), and cooling water temperature (10~55 °C) were selected as key variables, and an analysis was performed for a total of five conditions. A simulation was conducted to analyze the charging speed distribution, location of oxides and bubbles, and solidification pattern. As a result of the study, the flow of molten metal in the low and high-speed sections of the plunger, uniformity of product thickness, and supply conditions of the molten metal were confirmed to be major factors. It is important to manage the molten metal injection temperature at an appropriate level to minimize product defects. Based on these conditions, a prototype was manufactured, the microstructure was observed, and a fine and uniform grain structure was observed in most areas. In mechanical property evaluation, superior physical properties were secured compared to existing bulk materials.

The demand for lightweight and cost-effective heat sinks is increasing. A typical method for economically manufacturing complex-shape heat sinks is die casting. To reduce the weight of the die-cast heat sinks, thinning the fins and base is common practice. We experimented with casting heat sinks using Al-25%Si in a conventional die casting machine with the aim of economically producing thinner fins and bases. Compared with the aluminum alloy used in conventional die casting, Al-25%Si has superior fluidity, which is proven to be very useful for reducing the thickness of the fins and base. As a result, we successfully reduced the heat sink weight using Al-25%Si and a conventional die casting machine. To investigate the properties of the produced Al-25%Si thin fin heat sink, we compared the effects of fin thickness, fin height, number of fins, and base thickness on heat dissipation and weight reduction. Additionally, we compared the weight and heat dissipation properties with those of a commercial heat sink and found that our Al-25%Si heat sink maintains the same heat dissipation performance but for 35% lower weight.

Using 3D scanning, coordinate measuring machine, and roughness measurements we evaluated and compared zinc alloy castings produced in conventionally and additively manufactured shaped mould parts. Tests were conducted on castings from new shaped parts and subsequently after approximately every 100,000 shots. Castings from conventional parts had higher dimensional stability, but both types showed decreasing dimensional deviations over time. Castings from new additively manufactured parts had higher roughness initially, but this improved with use. Overall, there were no significant issues, and the benefits of additive-shaped parts prevailed. However, more testing is needed for a final recommendation for use in real operating conditions, requiring hundreds of thousands more shots.

The demand for aluminum in various fields continuously grows, including in the automotive industry. In this industry, aluminum is used as the material for the spare part. Therefore, aluminum with high mechanical properties and low casting defects is required. One of the available alternatives for producing excellent aluminum is through aluminum casting, including die casting. Die casting offers low cost in mass manufacturing of complex shaped components with acceptable casting results. Further, the selection of die-casting parameters and the addition of reinforcing elements can also improve the mechanical properties of aluminum. In this study, we strengthened the Al-Si matrix using High Pressure Die Casting process with particles from snail shell powder (calcium carbonate). Further, this study also explores the mechanical properties and microstructure of the product produced through experiment and optimization. The optimization was adopted to identify the optimum parameter. For the optimization, we used the Taguchi method. Our analysis results suggested that the reinforcing agent from the snail shell powder has the CaO and Ca(OH) _2 phases, with a crystallite size of 106.59 nm. The morphology of the shell powder reinforcing agent showed the presence of agglomeration and interconnected structures, such as skeletons, with average particle size of 0.4 micro. The functional group of the shell powder reinforcing agent showed the OH band during the water absorption by CaO, along with asymmetric C–O with vibration from the carbonate group and Ca–O bound. The most excellent hardness level was identified from T8, with 86.33 HRB and die casting parameters of 0.15% reinforce agents, 750 °C temperature injection, and 50 MPa pressure. Meanwhile, the best tensile strength was found from the T9 sample, with 109,95 MPa and die casting parameters of 0.15% reinforce agents, 800 °C temperature injection, and 60 MPa pressure. Microstructure on the used piston die casting sample with snail shell powder reinforcing agent showed the presence of Al, Si, dendrite, and Al _4 Ca phases. The multiple response analysis on the three factors indicated that the reinforcing agent presented the most significant effects toward the tensile strength and hardness, followed by pressure and temperature injection. Meanwhile, the Taguchi method and ANOVA results showed the optimal parameter die casting was obtained from a combination of 0.15 wt% reinforce agent, 800 °C injection temperature, and 50 MPa pressure. A multiple linear regression mathematical model for tensile strength and hardness was developed from the observed data. In regression model, the value of R ^2 of tensile strength 74.02% and R ^2 of the hardness is 95,18% Thus, the developed model can be effectively used to predict the tensile strength and hardness

Water-soluble salt core materials have high bending strength at room temperature. During high-pressure casting, water-soluble salt cores must withstand high temperatures and impact loads. To obtain a composite water-soluble salt core suitable for high-pressure casting components, sodium chloride and sodium carbonate are used as base salt materials. Ceramic particles of alumina are used as reinforcement materials in the preparation of a water-soluble composite salt core with excellent high-temperature strength via gravity casting. The microstructures of the salt core and fracture surface are observed and characterized. The use of alumina to enhance the sensitivity of the binary salt cores results in a low thermal crack sensitivity coefficient. The alumina particles dispersed in the matrix prevent crack propagation. Simulation results show that sodium aluminate has strong interfacial bonding abilities with other components in the salt core, affecting its high-temperature strength. Further results confirm that sodium aluminate formation enhances the high-temperature strength of salt cores. [ABSTRACT FROM AUTHOR]