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high-integrity die casting alloys

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Series: ASM Handbook
Volume: 2B
Publisher: ASM International
Published: 15 June 2019
DOI: 10.31399/asm.hb.v02b.a0006553
EISBN: 978-1-62708-210-5
... Abstract This article summarizes some general alloy groupings by application or major characteristics. The groupings include cast rotor, general-purpose, elevated-temperature, wear-resistant, moderate-strength, high-strength, and high-integrity die casting alloys and cast aluminum alloys...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005266
EISBN: 978-1-62708-187-0
... alloys can also be die cast. Parts produced by the die casting process are shown in Fig. 1 . The primary categories of the conventional die casting process are the hot chamber process and the cold chamber process. These main process variations have been enhanced in recent years to produce high-integrity...
Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006525
EISBN: 978-1-62708-207-5
...-integrity parts. In addition to vacuum technology, the article discusses casting alloys, dies, and cells, and describes some of the benefits of structural die castings. aluminum castings cold-chamber die casting die casting high-integrity die casting high-pressure die casting vacuum die casting...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005276
EISBN: 978-1-62708-187-0
... the injection of molten metal. The term vacuum die casting can mean any reduced pressure in the die cavity below atmospheric pressure. The method is widely used not only in conventional high-pressure die casting but also to some degree in the high-integrity, high-pressure die casting processes. Effective...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005269
EISBN: 978-1-62708-187-0
... aluminum alloys squeeze-casting tensile properties tooling design Squeeze Casting Squeeze casting ( Ref 1 , 2 , 3 , 4 ) is considered a high-integrity process and has emerged as an alternative to conventional casting techniques (gravity permanent mold, low-pressure permanent mold, sand...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005292
EISBN: 978-1-62708-187-0
... Abstract High-pressure die casting is a fast method for the net shape manufacturing of parts from nonferrous alloys. This article reviews the automation technologies for the different stages or steps of the process. These steps include liquid metal pouring, injection, solidification, die open...
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 December 1998
DOI: 10.31399/asm.hb.mhde2.a0003127
EISBN: 978-1-62708-199-3
... thinner than those obtainable by sand or permanent mold casting. High mechanical properties and resistance to fatigue can be developed in die castings without heat treatment because of the fine microstructures produced by the rapid solidification. Alloys most frequently used in die casting differ...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005288
EISBN: 978-1-62708-187-0
... the complete process of melting, alloying, holding, and casting takes place in one self-contained furnace ( Ref 1 ). The Unicast furnace differs from the modern version only in that refractory brick insulation is used hout instead of low-thermal-mass insulation. The integrated melting, homogenizing...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005261
EISBN: 978-1-62708-187-0
.../pressure riserless casting process for casting aluminum. metal casting furnaces pressure riserless casting casting aluminum low-pressure casting vacuum riserless LOW-PRESSURE METAL CASTING has been used since the 1950s to produce high-volume, high-integrity castings in alloys ranging from...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005333
EISBN: 978-1-62708-187-0
... oxyacetylene flame. Stud welding has been used, but it is not satisfactory, because the alloy adjacent to the stud is weakened and may break. Adhesive Bonding When appropriate, zinc die castings can be bonded with a range of modern high-strength adhesives, particularly those based on epoxy and phenolic...
Series: ASM Handbook
Volume: 9
Publisher: ASM International
Published: 01 December 2004
DOI: 10.31399/asm.hb.v09.a0003790
EISBN: 978-1-62708-177-1
... including aluminum, magnesium, zinc, titanium, and copper, as well as numerous ferrous alloys. In general, any alloy with a wide freezing range is suitable for use in semisolid metalworking. Most semisolid metalworking processes in use today parallel high-pressure die casting. As such, aluminum...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005272
EISBN: 978-1-62708-187-0
... of high-integrity die-cast-type components. The key to SSM processing is to generate a semisolid metal slurry that contains a globular primary phase (surrounded by the enriched liquid phase) and exhibits thixotropic behavior. That is, the viscosity of the slurry decreases continuously under shear...
Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006524
EISBN: 978-1-62708-207-5
... casting, is also included. alloying elements aluminum casting alloys high-pressure die casting low-pressure permanent mold casting permanent mold casting green sand casting investment casting castability ALUMINUM CASTINGS have played an integral role in the growth of the aluminum...
Book Chapter

By Justin Heimsch
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005273
EISBN: 978-1-62708-187-0
... in thixocasting. The article illustrates the differences between a conventional high-pressure die-casting injection profile and the thixocasting injection profile used to produce the same part. thixocasting billet sawing rheological tests high-pressure die-casting injection SEMISOLID METAL CASTING...
Book Chapter

Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005307
EISBN: 978-1-62708-187-0
... are frequently an integral part of the die casting machine. Most furnaces for melting and alloying, as well as for holding, are fuel-fired open-pot, immersion tube heated, or induction heated. Most pots for melting and containing molten zinc alloys are cast from gray or ductile cast iron. Ladles, if used...
Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006498
EISBN: 978-1-62708-207-5
... to be poured like a liquid, and these processes commonly use die casting alloys to produce die-cast-like components, but with reduced porosity and overall higher quality. Examples of each of the process are provided subsequently. High-Solid-Fraction Rheocasting As noted previously, the solid content...
Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006513
EISBN: 978-1-62708-207-5
... on Al-Si alloy. (a) Unrefined high-pressure die casting (HPDC) chain-saw crankcase, >150 °C/s (85 °F/s). (b) Gravity permanent-mold piston, ∼10 °C/s (5 °F/s). (c) Sand-cast engine prototype, <1 °C/s (0.5 °F/s). Original magnification: ∼75×. The gravity-fed casting (b) and sand casting (c) were AlP...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005318
EISBN: 978-1-62708-187-0
... die casting product. The flow is complex, and success depends on process simulation coupled with experience to provide high-quality die castings. Heat Removal Once the molten alloy is in the die cavity, the heat in the alloy must be removed to allow solidification and subsequent cooling...
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0009020
EISBN: 978-1-62708-187-0
... Moderate(+) tendency Little/moderate Nonferrous Aluminum 356, 357 Excellent Eutectic-type Little 1300–1400 °F High tendency Moderate Aluminum 201, 206 Good/fair Equiaxed Moderate 1300–1400 °F High tendency Moderate/large Aluminum die-cast alloys are dominated by the diecasting...
Series: ASM Handbook
Volume: 2
Publisher: ASM International
Published: 01 January 1990
DOI: 10.31399/asm.hb.v02.a0001061
EISBN: 978-1-62708-162-7
..., motors with high starting torque) the more highly alloyed die casting compositions are commonly used. The most popular are Alloys 443.2 and A380.2. By choosing alloys such as these, conductivities from 25 to 35% IACS can be obtained; in fact, highly experimental alloys with even higher resistivities have...