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Simulation Aspects of the High Pressure Die Casting Process
521-529Views:76High 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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Casting Issues of Thick-Walled High Pressure Die Castings
159-166Views:132Die 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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Application of Additive Technology in Precision Casting
43-56Views:180In this paper the surface of the prepared test specimens had been examined with light microscopy and surface roughness measurements. In order to improve the surface smoothness of PLA specimens, application of ethyl acetate was required. After this surface treatment, microscopic images were taken again. The melting and decomposition temperatures of the materials had been determined using derivatography. The chosen method was precision casting with gypsum molding. Also, the plaster molds had been burnt out according to the predefined melting and firing diagram. The measurement series shows that the samples produced by 3D printing can also be used in the field of precision casting. They provide greater freedom of design, more sophisticated pieces, and prototypes can be finished in a shorter amount of time.
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The Pressure Characteristics of the Released Gases from Sand Cores
73-79Views:132The core packages used for the production of castings are generally made from cores of different quality (no- bake phenol, HB-phenol, and HB-furan) and resin quantity, to meet the various requirements for the casting. In our research, the effect of the amount of resin on the pressure of the gases evolved from the cores was investigated. Experiments have shown that increasing the amount of resin has a different effect on different binder systems.
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Investigation on Double Oxide Film Initiated Pore Formation in Aluminum Casting Alloys
141-153Views:316The most common, and in fact, the most deleterious defects of aluminum casting alloys are the so-called double oxide films or bifilms, which have a central role in porosity formation, as they can easily unfurl and inflate into pores during the solidification of the alloys. Sr addition is generally used in the foundry industry for the modification of the eutectic Si phase of hypoeutectic Al-Si alloys. However, Sr microalloying usually leads to an increased pore formation tendency. As bifilms are preferred sites for pore formation, it should be expected that Sr additions have a significant effect on the number and/or the structure of double oxide films present in the melt. In this work, the relationship between Sr-concentration and the susceptibility to pore formation has been investigated through the evaluation of melt quality of melts which had different levels of Sr. The bifilm content of the melts was investigated by the analysis of K-mold specimens and X-ray computed tomography (CT) of reduced pressure test (RPT) samples. It was found that liquid alloys with a higher Sr concentration had a significantly greater tendency to pore formation, which can be explained by the presence of a larger number of bifilm defects in the liquid alloy.
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Investigation of the Granulometric and Mechanical Properties of Inorganic Used Sand
302-308Views:149This paper examines the use of a modified inorganic binder in metal-alloy casting. The results of investigations regarding the effect of reusing the used sand multiple times without reclamation. The technological properties of silica sand with inorganic binders were presented, two different temperatures were applied to make the used sands. After lump crushing the inorganic used sand was recycled in order to make a new sand mixture. Our work was focused on the effect of multiple usage of inorganic used sands on the mechanical and granulometric properties prepared with modified inorganic binder.
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Design of Manufacturing Process of Mould for Die Casting by EDM Technology with the Computer Aided
57-63Views:181At present, we cannot imagine a modern production process without computer support. At the same time, its integral part is the implementation of advanced and highly sophisticated production processes and technologies. Their aim is first and foremost to ensure quality production of products with high economic efficiency of the production process. EDM technology is one of the currently active progressive technologies. This is a technology that in practice is characterized by high product quality. The high quality of products not only through this progressive technology, but also other, whether conventional or progressive, is difficult to achieve without computer support. The aim of the paper is therefore to demonstrate the process of manufacturing a die-casting mould using progressive EDM technology using computer support.
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The Effect of Sizes of the Cast Polyamide 6 Rods upon Tensile-Impact Strength
21-24Views:120We have studied the tensile-impact strength of the magnesium catalysed cast polyamide 6 (PA6) rods according to the EN ISO 8256:2004 standard. The purpose of our investigation was to follow: the mechanical properties of rods are mapped beside same casting technological process in case of different diameters. We have compared the received results with each other than have sought disparities. We examined cylindrical product (rod) in seven dimensional steps in diameter ranging from 40 mm to 300 mm. We have determined that the semi-finished products can be divided into two groups typically in case of their tensile-impact strengths in this size range. The tensile-impact strength is higher in case of the rods with a diameter of less than 100 mm and it is smaller in the larger dimension range. Therefore, the smallest tensile-impact strength can be established in case of the natural semifinished PA6 rods that each rod accomplishes independently of size. However, a range can be determined, which the tensile-impact strength values of product are separated according to the manufacturing size
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The Effect of Fluxes on the Melt Quality of AlSi7MgCu Alloy
372-380Views:179The presence of inclusions such as oxides, carbides or refractory particles can be harmful to the mechanical and surface characteristics of castings. Inclusion-rich metals result in lower fluidity and feeding capability during casting. Nowadays, solid fluxes are widely used in foundries in order to reduce the inclusion content of aluminium melts. In this study, the effect of four different fluxes on the melt quality was studied. First, the inclusion content of the flux-treated melt, and then the properties of the fluxes (i.e. chemical composition and melting temperature) were examined.
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Investigation of Aluminum Dross as a Potential Asphalt Filler
445-451Views:90There is a great concern about utilizing different waste materials all over the world. Stockpiling in landfills is not a final solution, therefore researchers try to find alternative methods to utilize these materials [1-5]. One potential area may be road construction. Fillers are one of the most important components of asphalt pavements. It has a dual role. First of all, these fine grained mineral materials (d<0.063 mm) enhance the cohesion with bitumen. Second is to fill the gaps between the particles to produce more compact mixture [6]. The aim of this research is to reveal the possibility of utilization of aluminum dross as a potential asphalt filler. This material, which is a by-product of aluminum casting process, is produced in large quantities year by year and its storage in landfills is not a proper solution. Therefore, there is an increasing demand to utilize this material. During the research material structural tests were made, which can characterize the samples (limestone powder, dross), and the cohesion between bitumen and filler can also reveal. Particle size distribution, BET specific surface area and porosity were investigated. Scanning electron micrographs were taken and oil adsorption test were also made.
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Analysis of a Special, 3D Metal-Printed HPDC Tool Material
251-265Views:152High Pressure Die Casting (HPDC) is still the most productive metal-casting method of our time, however the more demanding are the industrial expectations, the more challenging it becomes to ensure the creation of the difficult cavity geometries and the thermal balance of the die-cast tool. New perspective is required, thus we can utilize high heat-conductivity tool steels and additive manufacturing technology.
