High Integrity Die Casting Processes
High Integrity Die Casting Processes

Author: Edward J. Vinarcik

Publisher: John Wiley & Sons

Published: 2002-10-16

Total Pages: 253

ISBN-13: 0471275468

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"It's about time that a practicing engineer with casting and academic experience has written a book that provides answers to questions about squeeze casting and semi-solid molding/forming that many engineers and students of casting need answered." —Joseph C. Benedyk, PhD, Consultant and retired technical director, Alcoa High Integrity Die Casting Processes provides a comprehensive look at the concepts behind advanced die casting technologies, including vacuum die casting, squeeze casting, and several variants of semi-solid metalworking. Practical applications for these processes are illustrated in numerous case studies. This single-source reference tool presents the latest material in 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, strategies to overcome the limitations of conventional die casting, and potential defects unique to high integrity die casting processes. Also featured are methods for minimizing porosity, reducing cost by design, practical applied statistical process control techniques, designing for manufacturability, and containment methods for potential processing defects. Several chapters present detailed real-world examples illustrating the broad range of applications possible 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 for training purposes in conjunction with numerous study questions designed to practically apply the content of the book to real-world situations. Selected PowerPoint(r) slides can be used to support engineering proposals, marketing presentations, or customer education seminars. High Integrity Die Casting Processes is a valuable reference for both component producers and component users alike. Process engineers, tool designers, manufacturing engineers, production managers, and machine operators will acquire a better understanding of these advanced die casting processes to optimize manufacturing and improve product quality. Component designers, product engineers, purchasing agents, buyers, supplier quality engineers, and project managers will gain insight into these processes and develop superior products by design.

Developments in Lightweight Aluminum Alloys for Automotive Applications
Developments in Lightweight Aluminum Alloys for Automotive Applications

Author: James M Boileau

Publisher: SAE International

Published: 2006-02-03

Total Pages: 551

ISBN-13: 1468603337

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The use of lightweight materials in automotive application has greatly increased in the past two decades. A need to meet customer demands for vehicle safety, performance and fuel efficiency has accelerated the development, evaluation and employment of new lightweight materials and processes. The 50 SAE Technical papers contained in this publication document the processes, guidelines, and physical and mechanical properties that can be applied to the selection and design of lightweight components for automotive applications. The book starts off with an introduction section containing two 1920 papers that examine the use of aluminum in automobiles.

Aluminum Alloy Castings
Aluminum Alloy Castings

Author: John Gilbert Kaufman

Publisher: ASM International

Published: 2004-01-01

Total Pages: 350

ISBN-13: 0871708035

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J. G. (Gil) Kaufman is currently president of his consulting company, Kaufman Associates.

Process and Tool Design for the High Integrity Die Casting of Aluminum and Magnesium Alloys
Process and Tool Design for the High Integrity Die Casting of Aluminum and Magnesium Alloys

Author: Varun Nandakumar

Publisher:

Published: 2014

Total Pages: 85

ISBN-13:

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The push for higher efficiency and lower emissions on present day automobiles have created a greater need for light alloys such as Aluminum and Magnesium to replace the customary steel parts in an automobile. A lot of these replaced parts are in structural load bearing components on a vehicle. This usually meant that processes such as the traditional High Pressure Die Casting would not be able to claim a stake in it due to its innate air and Hydrogen entrapment issues. But, with an overall higher maintenance of quality in the traditional process, it is possible to create higher integrity parts that are usable in structural applications. This thesis describes and tests some methods to improve the traditional High Pressure Die Casting process to enable it to produce higher integrity casts for Aluminum and Magnesium alloys. Methods to achieve a higher quality melt are researched and a rotary degasser is used for two experimental trials of similar Aluminum alloys. Similarly, methods to integrate vacuum into the existing setup are studied and the tooling part of the vacuum assist system with chill blocks is fully designed. The design of the chill blocks is carried out from the ground up using MAGMA and ANSYS simulation tools which were available at the Integrated Systems Engineering Lab. A designed experiment is completed to understand the effects of changing parameters on the design. Finally, the optimum design is completed on 3D CAD software and then manufactured in house.

Fundamentals of Aluminium Metallurgy
Fundamentals of Aluminium Metallurgy

Author: Roger Lumley

Publisher: Elsevier

Published: 2010-11-25

Total Pages: 862

ISBN-13: 0857090259

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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

Die Casting: Dies—Machines—Methods
Die Casting: Dies—Machines—Methods

Author: Chester L. Lucas

Publisher: Good Press

Published: 2021-05-19

Total Pages: 75

ISBN-13:

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This work describes the origin, procedure, and advantages of Die casting. It is a metal casting technique in which one pushes molten metal under high pressure into a mold cavity. Along with presenting the general facts on the subject, the writer goes into detail, explaining the operation of die casting machines, the process of making dies, and some quick tips to help the manufacturers improve efficiency. In addition, the book contains a chapter dedicated to the die casting company E. B. Van Wagner Mfg. Co., illustrating how their operations are carried out. Contents include: Die Casting Making Dies for Die-Casting Machines Van Wagner Mfg. Co.'s Die-Casting Practice

Material and Process Design for Lightweight Structures
Material and Process Design for Lightweight Structures

Author: Talal Al-Samman

Publisher: MDPI

Published: 2019-05-27

Total Pages: 162

ISBN-13: 3038979589

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The use of lightweight structures across several industries has become inevitable in today’s world given the ever-rising demand for improved fuel economy and resource efficiency. In the automotive industry, composites, reinforced plastics, and lightweight materials, such as aluminum and magnesium are being adopted by many OEMs at increasing rates to reduce vehicle mass and develop efficient new lightweight designs. Automotive weight reduction with high-strength steel is also witnessing major ongoing efforts to design novel damage-controlled forming processes for a new generation of efficient, lightweight steel components. Although great progress has been made over the past decades in understanding the thermomechanical behavior of these materials, their extensive use as lightweight solutions is still limited due to numerous challenges that play a key role in cost competitiveness. Hence, significant research efforts are still required to fully understand the anisotropic material behavior, failure mechanisms, and, most importantly, the interplay between industrial processing, microstructure development, and the resulting properties. This Special Issue reprint book features concise reports on the current status in the field. The topics discussed herein include areas of manufacturing and processing technologies of materials for lightweight applications, innovative microstructure and process design concepts, and advanced characterization techniques combined with modeling of material’s behavior.