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High Integrity Die Casting Processes

Author: Edward J. Vinarcik
Publisher: John Wiley & Sons
ISBN: 9780471275466
Size: 65.20 MB
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"It's about time that a practicing engineer with casting andacademic experience has written a book that provides answers toquestions about squeeze casting and semi-solid molding/forming thatmany engineers and students of casting need answered." —Joseph C. Benedyk, PhD, Consultant and retired technicaldirector, Alcoa High Integrity Die Casting Processes provides acomprehensive look at the concepts behind advanced die castingtechnologies, including vacuum die casting, squeeze casting, andseveral variants of semi-solid metalworking. Practical applicationsfor these processes are illustrated in numerous case studies. This single-source reference tool presents the latest materialin five sections: Basic concepts of die casting and molten metal flow High integrity die casting processes with case studies Product design considerations Controlling quality and avoiding defects Future advances under development Key coverage includes a survey of liquid metal flow, strategiesto overcome the limitations of conventional die casting, andpotential defects unique to high integrity die casting processes.Also featured are methods for minimizing porosity, reducing cost bydesign, practical applied statistical process control techniques,designing for manufacturability, and containment methods forpotential processing defects. Several chapters present detailedreal-world examples illustrating the broad range of applicationspossible using high integrity die casting processes. Included with this book is a CD-ROM containing PowerPoint(r)presentations for each chapter. These presentations can be used fortraining purposes in conjunction with numerous study questionsdesigned to practically apply the content of the book to real-worldsituations. Selected PowerPoint(r) slides can be used to supportengineering proposals, marketing presentations, or customereducation seminars. High Integrity Die Casting Processes is a valuablereference for both component producers and component users alike.Process engineers, tool designers, manufacturing engineers,production managers, and machine operators will acquire a betterunderstanding of these advanced die casting processes to optimizemanufacturing and improve product quality. Component designers,product engineers, purchasing agents, buyers, supplier qualityengineers, and project managers will gain insight into theseprocesses and develop superior products by design.

Aluminum Alloy Castings

Author: John Gilbert Kaufman
Publisher: ASM International
ISBN: 0871708035
Size: 61.81 MB
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J. G. (Gil) Kaufman is currently president of his consulting company, Kaufman Associates.

Metallurgy And Processing Of High Integrity Light Metal Pressure Castings

Author: Helmut Kaufmann
Publisher: Fachverlag Schiele & Schön
ISBN: 3794908813
Size: 44.73 MB
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Very sophisticated pressure casting equipment, such as High Pressure Die Casting (HPDC) machines with hydraulic shot control, Vertical Squeeze Casting machines and various Semi-solid Casting machines are used in modern foundries today. Nevertheless, the increasing geometrical complexity and technical requirements of light metal pressure castings have rendered process stability and castability a permanent issue for foundry men. The castings should be simultaneously light, strong, ductile, weldable, heat treatable, and pressure tight. In order to achieve these goals a process chain approach comprising a significant materials science component must be applied to aid product, alloy and process improvement. The contents of this book involve just such a process chain approach. In addition to the principles of pressure casting, the effects of melt quality, alloy composition, filling conditions, and even post-processing aspects such as heat treatment are addressed. Parameters affecting process stability and productivity are also discussed. It is hoped that this book will help foundry management and foundry men on the shop floor to achieve future improvements in pressure casting.

Metallurgy And Processing Of High Integrity Light Metal Pressure Castings

Author: Peter J. Uggowitzer
Publisher:
ISBN: 3794908813
Size: 52.62 MB
Format: PDF, ePub
View: 2007
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Very sophisticated pressure casting equipment, such as High Pressure Die Casting (HPDC) machines with hydraulic shot control, Vertical Squeeze Casting machines and various Semi-solid Casting machines are used in modern foundries today. Nevertheless, the increasing geometrical complexity and technical requirements of light metal pressure castings have rendered process stability and castability a permanent issue for foundry men. The castings should be simultaneously light, strong, ductile, weldable, heat treatable, and pressure tight. In order to achieve these goals a process chain approach comprising a significant materials science component must be applied to aid product, alloy and process improvement. The contents of this book involve just such a process chain approach. In addition to the principles of pressure casting, the effects of melt quality, alloy composition, filling conditions, and even post-processing aspects such as heat treatment are addressed. Parameters affecting process stability and productivity are also discussed. It is hoped that this book will help foundry management and foundry men on the shop floor to achieve future improvements in pressure casting.

Fundamentals Of Aluminium Metallurgy

Author: Roger Lumley
Publisher: Elsevier
ISBN: 0857090259
Size: 45.70 MB
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Aluminium is an important metal in manufacturing, due to its versatile properties and the many applications of both the processed metal and its alloys in different industries. Fundamentals of aluminium metallurgy provides a comprehensive overview of the production, properties and processing of aluminium, and its applications in manufacturing industries. Part one discusses different methods of producing and casting aluminium, covering areas such as casting of alloys, quality issues and specific production methods such as high-pressure diecasting. The metallurgical properties of aluminium and its alloys are reviewed in Part two, with chapters on such topics as hardening, precipitation processes and solute partitioning and clustering, as well as properties such as fracture resistance. Finally, Part three includes chapters on joining, laser sintering and other methods of processing aluminium, and its applications in particular areas of industry such as aerospace. With its distinguished editor and team of expert contributors, Fundamentals of aluminium metallurgy is a standard reference for researchers in metallurgy, as well as all those involved in the manufacture and use of aluminium products. Provides a comprehensive overview of the production, properties and processing of aluminium, and its applications in manufacturing industries Considers many issues of central importance in aluminium production and utilization considering quality issues and design for fatigue growth resistance Metallurgical properties of aluminium and its alloys are further explored with particular reference to work hardening and applications of industrial alloys

Analyse Und Numerische Simulation Von Freien Oberfl Chenwellen In Der Gie Kammer Eines Druckgie Prozesses

Author: Roudouane Laouar
Publisher: kassel university press GmbH
ISBN: 3862195805
Size: 27.62 MB
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Die Ausbreitung von Oberflächenwellen an der Phasengrenzfläche zwischen einer Flüssigkeit und einem Gas kommt sowohl in der Natur als auch in der Technik häufig vor. In zeitabhängigen Prozessen ist die freie Oberfläche in der Regel nicht fest, sondern sie ändert ihre Lage in Abhängigkeit von Ort und Zeit. Zur Prognose der Strömung selbst sowie für die entstehenden Kräfte und Momente ist es daher erforderlich, die Bewegung der freien Oberfläche simultan zu bestimmen. Unter stark einschränkenden Bedingungen, z. B. Reibungsfreiheit und unter Ausnutzung von zeitlichen Periodizitäten, gelingt es dafür analytische Lösungen herzuleiten. Spielen jedoch die Reibung und andere Materialeigenschaften eine nicht zu vernachlässigende Rolle und ist zudem das Strömungsgebiet nicht mehr geometrisch einfach, können nur noch das Experiment oder die numerische Simulation zu Rate gezogen werden. In diesem Zusammenhang beschäftigt sich die vorliegende Arbeit mit der Analyse, Modellierung und numerischen Simulation der Ausbildung von Oberflächenwellen während des Füllvorgangs einer Kaltkammerdruckgießzelle. Der Fokus liegt auf dem Vorschub der flüssigen bzw. teilerstarrten Aluminiumschmelze-Suspension durch einen Kolben während der ersten Füllphase der Füllkammer. Die grundlegende Zielsetzung liegt darin, schädliche Gas- und Oxideinschlüsse zu vermeiden und Optimierungspotentiale aufzuzeigen. Dabei wird der Einfluss der Geschwindigkeit bzw. Beschleunigung des Kolbens sowie der Einfluss der Oberflächenspannung auf die Wellenbewegung untersucht. Die Auswirkung der temperaturabhängigen strukturviskosen Eigenschaften von teilflüssigen Metallschmelzen auf das Wellenausbreitungsverhalten ist ein Bestandteil dieser Arbeit. Die numerischen Simulationsrechnungen wurden mit dem kommerziellen Software-Programm FLUENT durchgeführt. Das Mehrphasenberechnungsverfahren basiert auf der Finiten-Volumen-Methode und verwendet die VOFMethode zur Beschreibung der freien Phasengrenze. Es wurden zwei- und dreidimensionale Berechnungen durchgeführt.

Asm Handbook

Author: ASM International. Handbook Committee
Publisher: ASM International
ISBN: 087170711X
Size: 29.76 MB
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ASM Handbook, Volume 15 is a comprehensive reference on the principles and practice of metalcasting, covering fundamentals, process selection and parameters, and materials performance. This reference work is designed for those who specify, manufacture, design or evaluate cast metal components. This broad-based collection of applied casting knowledge provides a valuable resource for students, educators, practicing engineers, and technical support staff. The latest edition of Volume 15 updates and expands coverage on the principles and practices of casting in several ways: Melt processing methods and equipment are described for iron, steel, and aluminum in terms of fluxing, degassing, molten metal filtration, refinement, and modification. Solidification, process modeling, and filling and feeding concepts are updated to reflect the continuing improvements in casting methods and processing. The major methods of green-sand, no-bake, and shell molding are described further in individual articles. Additional articles are devoted to the foundry practice of cast iron irons, steels, aluminum, copper alloys, and zinc. Expert updates are also provided on many other significant casting methods such as high-pressure die casting, lost-foam, squeeze casting, semisolid methods, spray casting, rapid solidification, and low-pressure die casting of high-integrity product. Automation technology is addressed, and coverage on continuous casting of aluminum and copper are expanded. Updated articles are also provided on the specification, selection, and properties of gray iron, ductile irons, malleable irons, compacted graphite irons, high-alloy irons, cast steels, aluminum, copper, zinc, magnesium, cobalt, nickel, titanium, zirconium, and cast metal matrix composites. Contents include: Introduction (History, Trends, and Purchasing Castings); Principles of Liquid Metal Processing; Melting and Remelting; Molten Metal Handling and Processing; Principles of Solidification; Modeling and Analysis of Casting Processes; Principles and Practices of Shape Casting; Expendable-Mold Casting with Permanent Patterns; Expendable-Mold Casting with Expendable Patterns; Centrifugal Casting; Permanent Mold and Semi-permanent Mold Processes ; High-Pressure Die casting; Cast Irons ; Steel Castings ; Nonferrous Casting Practices; Nonferrous Castings; Quality Assurance, Nondestructive Evaluation, and Failure Analysis