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Die castings
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001641
EISBN: 978-1-62708-235-8
... Abstract Near-surface porosity in zinc die castings that were subsequently plated with copper, nickel, and bright chromium was causing blemishes in the plating. Identifying die casting turbulence and hot spots were keys to process modifications that subsequently allowed porosity to be greatly...
Abstract
Near-surface porosity in zinc die castings that were subsequently plated with copper, nickel, and bright chromium was causing blemishes in the plating. Identifying die casting turbulence and hot spots were keys to process modifications that subsequently allowed porosity to be greatly minimized.
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001120
EISBN: 978-1-62708-214-3
... Abstract A segment from a premium-quality H13 tool steel die for die casting of aluminum failed after only 700 shots. The segment was subjected to visual, macroscopic, hardness, and metallographic testing. The investigation revealed that failure occurred as a result of fatigue at an electrical...
Abstract
A segment from a premium-quality H13 tool steel die for die casting of aluminum failed after only 700 shots. The segment was subjected to visual, macroscopic, hardness, and metallographic testing. The investigation revealed that failure occurred as a result of fatigue at an electrical-discharge-machined surface where the resulting rehardened layer had not been removed. This rehardened layer had cracked, providing a source for fatigue initiation.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0048620
EISBN: 978-1-62708-225-9
.... Fasteners Intergranular corrosion Zinc-aluminum die casting alloy Stress-corrosion cracking The two nuts shown in Fig. 1(a) and (b) were used to secure the water-supply pipes to the threaded connections on hot-water and cold-water taps. The nut used on the cold-water tap ( Fig. 1a ) fractured...
Abstract
Two nuts were used to secure the water-supply pipes to the threaded connections on hot-water and cold-water taps. The nut used on the cold-water tap fractured about one week after installation. Examination of the fracture surfaces of the coldwater nut did not reveal any obvious defects to account for the fracture, but there were indications of excessive porosity in the nut. The fracture had occurred through the root of the first thread that was adjacent to the flange of the tap. It was found that the nut from the cold-water tap failed by SCC. Apparently, sufficient stress was developed in the nut to promote this type of failure by normal installation because there was no evidence of excessive tightening of the nut. Corrosion testing of the nuts indicated that the fractured nut was highly susceptible to intergranular corrosion because of either a deficiency in magnesium content or excessive impurities, such as lead, tin, or cadmium. This composition problem with zinc alloys was recognized many years ago, and particular attention has been directed toward ensuring that high-purity zinc is used. This corrective measure reportedly resulted in virtual elimination of this type of defect.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.homegoods.c0090971
EISBN: 978-1-62708-222-8
... Abstract A die-cast zinc adapter used in a snowthrower failed catastrophically in a brittle overload manner. The component had a chemical composition similar to standard zinc alloy ZA-27 (UNS Z35840), although the iron content was much higher and the copper slightly lower. The mechanical...
Abstract
A die-cast zinc adapter used in a snowthrower failed catastrophically in a brittle overload manner. The component had a chemical composition similar to standard zinc alloy ZA-27 (UNS Z35840), although the iron content was much higher and the copper slightly lower. The mechanical properties and alloy designation were not specified. Investigation (visual inspection, 187x SEM images, unetched 30x images, hardness testing, and chemical analysis) of both the failed adapter and an exemplar casting from known-good lot supported the conclusion that the casting failed as a result of brittle overload fracture due to excessive iron-zinc phase and gross porosity. These conditions acted synergistically to reduce the strength of the material. The composition was nonstandard, and the inherent brittleness suggested that it was unlikely that this material was an intentional proprietary alloy. No recommendations were made.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001908
EISBN: 978-1-62708-235-8
... Abstract Cluster bomb tailcone assemblies each containing two aluminum die-cast components were rejected because of the poor surface condition of the die castings. Numerous heat checks were found on the surfaces of the tailcones and radiographic inspection revealed inclusions, gas holes...
Abstract
Cluster bomb tailcone assemblies each containing two aluminum die-cast components were rejected because of the poor surface condition of the die castings. Numerous heat checks were found on the surfaces of the tailcones and radiographic inspection revealed inclusions, gas holes, and shrinkage defects in the castings. Most of the components failed to meet required mechanical properties because of these casting defects.
Image
in Brittle Overload Failure of Die- Cast Zinc Snowthrower Adapters
> ASM Failure Analysis Case Histories: Household Products and Consumer Goods
Published: 01 June 2019
Fig. 1 Brittle overload of a die-cast zinc snowthrower adapter. (a) Fracture surface of failed zinc casting contained many large brittle constituents. Energy-dispersive spectroscopy analysis revealed these were high-iron content inclusions. Scanning electron micrograph. 178×. (b
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in Stress-Corrosion Cracking of a Die-Cast Zinc Alloy Nut
> ASM Failure Analysis Case Histories: Mechanical and Machine Components
Published: 01 June 2019
Fig. 1 Die-cast zinc alloy nuts from a water tap. (a) Nut for the cold-water tap that failed by SCC. (b) Mating nut for the hot-water top that shows only isolated areas of corrosion. (c) Unetched section showing metal in the cold-water tap after corrosion testing. 600×
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in Plating Blemishes in Zinc Die Castings
> ASM Failure Analysis Case Histories: Processing Errors and Defects
Published: 01 June 2019
Fig. 1 A classical “gas” pore in a zinc die casting. It has been opened to the surface of the part by the buffing operation performed prior to electroplating.
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Published: 01 January 2002
Fig. 19 Brittle overload of a die-cast zinc snowthrower adapter ( example 8 ). (a) Fracture surface of failed zinc casting contained many large brittle constituents. Energy-dispersive spectroscopy analysis revealed these were high-iron content inclusions. Scanning electron micrograph. 178×. (b
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Image
Published: 01 January 2002
Fig. 23 Metallographic specimens from two aluminum die cast specimens. (a) View showing mount prepared from the fractured die castings. (b) Macrograph of the mount showing porosity (white spots) from polishing media and/or debris embedded in the pores. (c) Light micrograph showing the extent
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Published: 01 January 2002
Fig. 24 SEM images from fracture surface of aluminum die casting. (a) 20.5×. (b) Shrinkage pores visible as dendritic structure. 164×. (c) View showing gas pore and intercellular fracture. 410×. (d) Mixture of gas (smooth, spherical) pores and shrinkage pores. 410×
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Published: 01 January 2002
Fig. 28 Erosion damage and misaligned bore of the AISI H13 tool steel zinc die casting nozzle shown in Fig. 27 after longitudinal splitting. Actual size
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Published: 30 August 2021
Fig. 11 Die-cast zinc alloy nuts from a water tap. (a) Nut for the cold-water tap that failed by stress-corrosion cracking. (b) Mating nut for the hot-water top that shows only isolated areas of corrosion. (c) Unetched section showing metal in the cold-water tap after corrosion testing
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c9001222
EISBN: 978-1-62708-225-9
... Abstract A full lift disk, made of die cast brass, which served as a lifting aid in a safety valve, had cracked in service at a number of locations in the vicinity of the threaded hole. During microscopic examination, agglomeration of oxide inclusions were noted in the region of the cracks...
Abstract
A full lift disk, made of die cast brass, which served as a lifting aid in a safety valve, had cracked in service at a number of locations in the vicinity of the threaded hole. During microscopic examination, agglomeration of oxide inclusions were noted in the region of the cracks. Because the die cast brass was alloyed with aluminum, these inclusions consisted predominantly of aluminum oxide. The tolerable limit in pores and oxide inclusions was greatly exceeded in the lift disk under examination. Above all, the numerous oxide skins disrupted the cohesion of the microstructure and were primarily responsible for the failure of the lift disk.
Series: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001284
EISBN: 978-1-62708-215-0
... Abstract Compound bow handle risers that had failed in service and during assembly along with an unassembled riser were submitted for analysis. The risers were die cast from magnesium-base alloy AM60A. Inspection of the failed risers and metallurgical investigations conducted on the stock riser...
Abstract
Compound bow handle risers that had failed in service and during assembly along with an unassembled riser were submitted for analysis. The risers were die cast from magnesium-base alloy AM60A. Inspection of the failed risers and metallurgical investigations conducted on the stock riser revealed the presence of cold shuts at the same site in all specimens. It was recommended that all risers be thoroughly inspected and that the bow company work with their die casting shop to design a mold with acceptable filling characteristics.
Book Chapter
Series: ASM Handbook Archive
Volume: 11
Publisher: ASM International
Published: 01 January 2002
DOI: 10.31399/asm.hb.v11.a0003508
EISBN: 978-1-62708-180-1
... Abstract This article focuses on the general root causes of failure attributed to the casting process, casting material, and design with examples. The casting processes discussed include gravity die casting, pressure die casting, semisolid casting, squeeze casting, and centrifugal casting. Cast...
Abstract
This article focuses on the general root causes of failure attributed to the casting process, casting material, and design with examples. The casting processes discussed include gravity die casting, pressure die casting, semisolid casting, squeeze casting, and centrifugal casting. Cast iron, gray cast iron, malleable irons, ductile iron, low-alloy steel castings, austenitic steels, corrosion-resistant castings, and cast aluminum alloys are the materials discussed. The article describes the general types of discontinuities or imperfections for traditional casting with sand molds. It presents the international classification of common casting defects in a tabular form.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001199
EISBN: 978-1-62708-235-8
... Abstract Lakes in zinc die castings are areas encompassed by irregular lines or waves on flat or slightly contoured surfaces which are intended to look uniform. The laked areas have to be removed by polishing before the castings can be plated. This adds considerably to the overall cost...
Abstract
Lakes in zinc die castings are areas encompassed by irregular lines or waves on flat or slightly contoured surfaces which are intended to look uniform. The laked areas have to be removed by polishing before the castings can be plated. This adds considerably to the overall cost of production. Castings examined were of an automobile name-plate holder with two flat sides of approximately 113 sq cm. All castings produced during a trial showed laking defects, the number and position varying from casting to casting. It was found that formation of metal waves and lakes depended primarily on the design of the gate and runner system and operating conditions. High flow efficiencies, with adequate feeding to all sections of the die, and short cavity fill times are desirable.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001640
EISBN: 978-1-62708-235-8
... Abstract A new supplier for aluminum die castings was being evaluated, and the castings failed to meet the durability test requirements. Specifically, the fatigue life of the castings was low. Initial inspection of the fatigue fracture surfaces revealed large-scale porosity visible to the naked...
Abstract
A new supplier for aluminum die castings was being evaluated, and the castings failed to meet the durability test requirements. Specifically, the fatigue life of the castings was low. Initial inspection of the fatigue fracture surfaces revealed large-scale porosity visible to the naked eye. New castings with reduced porosity also failed the durability tests. The fatigue fracture surfaces of additional casting fragments were very rough and contained multiple ratchet marks along the inner fillet. These observations indicated the fatigue process was heavily influenced by the presence of surface imperfections. Improving the surface finish or choosing a stronger alloy, were more likely to improve part durability than reducing the porosity.
Series: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001123
EISBN: 978-1-62708-214-3
... Abstract Extensive cracking was found in a batch of die-cast ZAMAK 3 solenoid valve seats during commissioning of the system in which they were installed. Scanning electron microscopic and chemical analyses conducted on one of the failed valve seats showed that the composition of the alloy...
Abstract
Extensive cracking was found in a batch of die-cast ZAMAK 3 solenoid valve seats during commissioning of the system in which they were installed. Scanning electron microscopic and chemical analyses conducted on one of the failed valve seats showed that the composition of the alloy was different from that specified. The presence of excess aluminum and lead impurities that had segregated to the grain boundaries, coupled with an inadequate amount of magnesium, resulted in intergranular corrosion and subsequent intergranular failure. Corrosion was accelerated by storage in a humid environment in a coastal area. It was recommended that proper chemical analysis of the zinc-aluminum alloy be carried out as a quality control procedure.
Image
Published: 01 January 2002
Fig. 22 (a) Cold shut voids (A, B) and flow lines (C, D) both caused by failure of the streams of molten metal to merge, at the cast surface (E) of an alloy 384-F die casting. 0.5% hydroflouric acid. 53× (b) Gate area (A) of an alloy 413-F die casting that has a cold shut void (B) and a region
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