Search Results for high-pressure die-casting injection

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.

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.

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.

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.

This article describes the melting process of casting metals used in hot chamber die casting. It discusses the design and capabilities of injection components, such as gooseneck, plunger, and cylinder. The article reviews the distinctions between hot and cold chamber processes. An example of a typical runner, gate and overflow configuration for faucet fixture casting is shown. Temperature control for die casting is also discussed. The article explains some ejection and post-processing techniques used for the hot chamber die casting: robotics, recycling, and fluxing.

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.

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.

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.

The cold chamber die casting process is used with higher-melting-point alloys such as aluminum and magnesium. This article discusses the component design of the cold chamber high-pressure die casting machine. It reviews the process parameters of cold chamber die casting, incuding the shot profile, intensification phase, and component size.

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.

This article describes key processing methods and related design, manufacturing, and application considerations for plastic parts. The methods include injection molding, extrusion, thermoforming, blow molding, rotational molding, compression molding/transfer molding, composites processing, and casting. The article describes principal features incorporated into the design of plastic parts. It concludes with a discussion on the materials selection methodology for plastics.

Ceramic-forming processes usually start with a powder which is then compacted into a porous shape, achieving maximum particle packing density with a high degree of uniformity. This article compares and contrasts several forming processes, including mechanical consolidation, dry pressing, cold isostatic pressing, slip casting, tape casting, roll compaction, extrusion, and injection molding. It describes the advantages, equipment and tooling, and material requirements of green machining, the machining of ceramics in an unfired state with the intent of producing parts as close to as possible to their final shape. The article also provides useful information on drying methods, shrinkage, and defects as well as the removal of organic processing aids such as dispersants, binders, plasticizers, and lubricants.

Aluminum casting alloys are the most versatile of all common foundry alloys and generally have the highest castability ratings. This article provides an overview of the common methods of aluminum shape casting. These include gravity casting, die casting, sand casting, lost foam casting, shell mold casting, plaster casting, investment casting, permanent mold casting, squeeze casting, semisolid forming, centrifugal casting, and pressure die casting. The article presents several different factors on which the selection of a casting process depends. It discusses gating and risering principles in casting. The article concludes with information on premium engineered castings that provide higher levels of quality and reliability than in conventionally produced castings.

This article discusses the categories and subcategories of shape casting processes. These include single-use processes such as sand, plaster, ceramic, and graphite molding; essentially unpressurized multiuse processes, such as permanent mold; and high-pressure metal mold methods, such as die casting, squeeze casting, and semisolid processing. The article contains tables that compare some of the typical capabilities of shape casting processes.

This article discusses classification of foundry processes based on the molding medium, such as sand molds, ceramic molds, and metallic molds. Sand molds can be briefly classified into two types: bonded sand molds, and unbonded sand molds. Bonded sand molds include green sand molds, dry sand molds, resin-bonded sand molds, and sodium silicate bonded sand. The article describes the casting processes that use these molds, including the no-bake process, cold box process, hot box process, the CO2 process, lost foam casting process and vacuum molding process. The casting processes that use ceramic molds include investment casting, and plaster casting. Metallic molds are used in permanent mold casting, die casting, semisolid casting, and centrifugal casting.

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.

This article discusses technologies focused on processing plastic materials or producing direct tools used in plastics processing. The article focuses on extrusion and injection molding, covering applications, materials and their properties, equipment, processing details, part design guidelines, and special processes. It also covers the functions of the extruder, webline handling, mixing and compounding operations, and process troubleshooting. Thermoforming and mold design are covered. Various other technologies for polymer processing covered in this article are blow molding, rotational molding, compression molding, transfer molding, hand lay-up process, casting, and additive manufacturing.

This article reviews the pattern materials used in investment casting, which can be loosely grouped into waxes and plastics. The patternmaking process, pattern tooling, and pattern and cluster assembly are described. The article also describes the manufacture of ceramic shell molds and cores, detailing the binders and other materials used, as well as the formulation and control of slurries. Methods for pattern removal, mold firing, melting, casting, postcasting treatment, and inspection are explained. After presenting design recommendations for investment castings, the article concludes with information on applications and special versions of the investment casting process.

In general, metal-matrix composites (MMCs) are classified into three broad categories: continuous fiber-reinforced composites, discontinuous or short fiber-reinforced composites, and particle-reinforced composites. This article focuses on stir casting and melt infiltration as the two main methods of MMC solidification processing. It describes the MCC casting methods, such as sand and permanent mold casting, centrifugal casting, compocasting, and high-pressure die casting. The article discusses the MMC infiltration processes in terms of pressure infiltration casting and liquid metal infiltration. It reviews the powder metallurgy processing of aluminum MMCs and deformation processing of discontinuously reinforced aluminum composites. The article concludes with a discussion on the processing of fiber-reinforced aluminum.