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high-integrity die casting alloys
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Book Chapter
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...
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 bearings. A table lists selected applications for aluminum casting 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...
Abstract
This article provides a comprehensive discussion on die casting alloy types and casting processes used in high-pressure die casting. It presents the advantages and disadvantages of high-pressure die casting and describes the product design for the process. The article concludes with information on the metal injection process of high-pressure die casting.
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...
Abstract
Nearly two-thirds of the aluminum castings made in North America are produced using high-pressure die casting techniques. This article compares and contrasts traditional high-pressure die casting with an improved version that uses a vacuum to pull air out of the die in order to reduce porosity in as-cast parts. It begins by describing a typical cycle for a traditional cold-chamber die casting machine, using detailed illustrations to show how gas can become trapped in the liquid metal. It then presents various remedies, ultimately focusing on vacuum die casting for the production of high-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.
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...
Abstract
Vacuum high-pressure die casting uses a vacuum pump to evacuate the air and gases from the die casting die cavity and metal delivery system before and during the injection of molten metal. This article describes the conventional die casting, vacuum die casting, and high-pressure die casting processes.
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...
Abstract
This article discusses the types of squeeze-casting machines and the advantages of squeeze casting. It examines the considerations required for the casting and tooling design process of squeeze-casting. The article describes the various factors that affect the squeeze-cast products and outlines a few of the key process characteristics. It provides information on the applications of squeeze-cast and contains a table that compares the tensile, hardness, and impact properties of select squeeze-cast aluminum alloys with those obtained from conventional casting processes.
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...
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, part extraction, die lubrication, insert loading, and die close. Some manual aspects of the operations, together with automation options, are discussed. The article describes finishing steps, such as finish trimming, detailed deflashing, shot blast cleaning, and quality checks. Automation of the postcasting process is also discussed.
Book Chapter
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...
Abstract
Aluminum casting alloys are the most versatile of all common foundry alloys and generally have the highest castability ratings. Aluminum alloy castings are routinely produced by pressure-die, permanent-mold, green and dry-sand, investment, and plaster casting. This article describes factors affecting the selection of casting process and the general designation system for aluminum alloys. It provides useful information on mechanical test methods, selection of proper test specimens for accurate test methods, characteristics of premium engineered castings, and advantages of hot isostatic pressing.
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...
Abstract
This article reviews the history and methods of copper alloy continuous casting. These methods include vertical continuous casting and horizontal continuous casting. The article discusses the upcasting methods used in vertical continuous casting and strip casting used in horizontal continuous casting. The article also describes the methods and processes of wheel casting and the Ohno continuous casting method.
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...
Abstract
This article provides an overview of conventional low-pressure casting and describes types of furnaces, tooling, and cores. It discusses the casting cycle steps, advantages, mechanical properties, and considerations of counterpressure casting. The article describes the vacuum riserless/pressure riserless casting process for casting aluminum.
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...
Abstract
Die casting is the process most often used for shaping zinc alloys. This article tabulates the compositions of zinc casting alloys and comparison of typical mechanical properties of zinc casting alloys. It discusses additions of alloys to the zinc, including aluminum, magnesium, copper, and iron. The article illustrates a characteristic five-layer microstructure of zinc alloy casings. It discusses the various methods of finishing of zinc alloy die castings, including chromium plating, polishing, painting, and electropainting. The article describes the casting of inserts and their uses in the zinc. It concludes with information on the applications of zinc die castings.
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...
Abstract
This article begins with a description of indirect and direct semisolid metalworking processes. It then provides information on alloy compositions of common aluminum semisolid metalworking alloys and primary die-cast magnesium alloys in a tabular form. The article describes the macroscopic examination of defects, which occur in semisolid metalworking with illustrations. It discusses the macroscopic examination of gating systems and semisolid feedstocks. The article also provides information on feedstock microstructures, direct semisolid metalworking component microstructures, and indirect semisolid metalworking component microstructures of series 300 aluminum casting alloys and magnesium die-casting alloys.
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...
Abstract
Semisolid metal (SSM) processing, also known as semisolid metal casting, semisolid forming, or semisolid metal forging, is a special die casting process. This article discusses the origin and advantages of the SSM processing. It describes three major semisolid processing routes: thixocasting, rheocasting, and thixomolding.
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...
Abstract
Aluminum casting alloys are among the most versatile of all common foundry alloys and generally have high castability ratings. This article provides an overview of the common methods of aluminum shape casting. It discusses the designations of aluminum casting alloys categorized by the Aluminum Association designation system. The article summarizes the basic composition groupings of aluminum casting alloy and discusses the effects of specific alloying elements and impurities. The characteristics of the important casting processes are summarized and compared in a table. The article presents the advantages and disadvantages of green sand casting, permanent mold casting, semipermanent mold casting, and high-pressure die casting. A discussion on other casting processes, such as investment casting, lost foam, plaster mold casting, pressure casting, centrifugal casting, and semisolid casting, is also included.
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...
Abstract
This article provides an overview of the thixocasting process and discusses the concepts that are important to the practical application of this technology. The thixocasting process involves two casting processes. The first casting process is required to make the feedstock that must be reheated to achieve the structures necessary for casting. The second casting process combines billet sawing, reheating, and the actual injecting of material into the mold. The article focuses on these processes and provides information on rheological tests. It discusses some key design concepts used 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.
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...
Abstract
This article describes the control of alloy composition and impurity levels in die casting of zinc alloys based on agitation, use of foundry scrap, and melt temperature and fluxing. It reviews the process considerations for the melt processing of the zinc alloys. The process considerations include the usage of furnaces and launder system, scrap return, inclusions in zinc alloys, fluxing of zinc alloys, and galvanizing fluxes. The article discusses the materials and lubricant selection, casting and die temperature control, and trimming process used in hot chamber die casting for zinc alloys. It also reviews other casting processes for zinc alloys, such as sand casting, permanent mold casting, plaster mold casting, squeeze casting, and semisolid casting.
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...
Abstract
Semisolid casting is a near-net shape manufacturing process capable of producing thick- and thin-walled complex-shaped components having excellent mechanical and functional performance. This article begins with a discussion on the history of semisolid processing and the advantages claimed for semisolid casting. It describes the four notable processes used to produce semisolid castings: thixocasting, rheocasting, thixomolding, and wrought processes. Most commercial aluminum semisolid casters use either thixocasting or rheocasting. The article discusses the die design, process conditions, and simulation for semisolid casting. It concludes with a review of several components produced by each of the various semisolid casting processes.
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...
Abstract
Aluminum casting in steel and iron permanent molds is used widely throughout industry, and the vast majority of permanent mold castings are made of aluminum and its alloys. There are several methods used to cast aluminum in permanent molds. This article focuses on permanent mold casting with molten aluminum fed by gravity, low pressure, vacuum and centrifugal pressure, and squeeze casting. It discusses the major variables that affect the life of permanent molds, including pouring temperature, casting shape, cooling methods, heating cycles, storage, and cleaning. The article reviews the basic components of mold coatings: refractory fillers, binder, and carrier. Casting defects and suggested corrective actions for permanent mold casting are summarized in a table. The article concludes with a discussion on thin-wall permanent-mold castings.
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...
Abstract
The designer of die casting tooling must balance the functional requirements of the part being cast with the cost, speed, and quality requirements of the process. In addition, attention must also be paid to the capacity and operating parameters of the casting machines being used and the need and economics of postprocessing. This article examines how design and materials selection address these diverse requirements of conventional die casting tooling. It focuses on the tooling for high-volume processes where the liquid or semisolid metal is forced into the die with high pressure and speed. The article also describes the functions of the tooling which involves supplying of molten alloy to the casting machine and injecting it into the die.
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...
Abstract
Casting offers a great amount of component design flexibility. This article discusses six casting design parameters that drive the geometry of casting design from a process standpoint. It provides information on the design of junctions and addresses considerations of secondary operations in design. The article describes the factors that control casting tolerances and presents specific tips for designing castings with uniform wall thickness, unequal sections, thin sections, economical coring, functional packaging, and core design. The article provides a framework for analyzing all manners of manufacturing as possible conversion candidates for casting. It concludes with a discussion on different metalcasting design projects.
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...
Abstract
Aluminum casting alloys are the most versatile of all common foundry alloys and generally have the highest castability ratings. This article discusses the designation and classification of aluminum casting alloys based on their composition and the factors influencing alloy selection. Alloys discussed include rotor alloys, commercial duralumin alloys, premium casting alloys, piston and elevated-temperature alloys, general-purpose alloys, magnesium alloys, aluminum-zinc-magnesium alloys, and bearing alloys. Six basic types of aluminum alloys developed for casting include aluminum-copper, aluminum-copper-silicon, aluminum-silicon, aluminum-magnesium, aluminum-zinc-magnesium, and aluminum-tin. The article also describes the main casting processes for aluminum alloys, which include die casting, permanent mold casting, sand casting (green sand and dry sand), plaster casting, and investment casting. In addition, the article discusses factors affecting the mechanical and physical properties, microstructural features that affect mechanical properties, the effects of alloying, and major applications of aluminum casting alloys.
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