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Published: 01 December 2008
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005274
EISBN: 978-1-62708-187-0
... Abstract This article illustrates various rheocasting processes. These include new rheocasting, semisolid rheocasting, subliquidus casting, rheo-diecasting, swirled enthalpy equilibration device process, slurry-on-demand process, and continuous rheoconversion processes. rheocasting...
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
... rheocasting process variations. These include UBE's New Rheocasting (NRC) process, MIT's Semisolid Rheocasting (SSR) process, THT's Subliquidus Casting (SLC) process, Alcan's Swirl Enthalpy Equilibration Device (SEED), Brunel's Rheo-Diecasting process, Mercury-Marine's Slurry-on-Demand process, and WPI's...
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.
Book Chapter
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003420
EISBN: 978-1-62708-195-5
..., spheroidal solids floating in the liquid. Stirring at high speeds creates a high shear rate, which tends to reduce the viscosity of the slurry even at solid fractions as high as 50 to 60% volume. The process of casting such a slurry is called rheocasting . The slurry can also be mixed with particulates...
Abstract
Metal-matrix composites (MMCs) are a class of materials with a wide variety of structural, wear, and thermal management applications. This article discusses the primary processing methods used to manufacture discontinuous aluminum MMCs, namely, high-pressure die casting, pressure infiltration casting, liquid metal infiltration, spray deposition, and powder metallurgy methods. It describes the processing of continuous fiber-reinforced aluminum, discontinuously, reinforced titanium, and continuous fiber-reinforced titanium. The article concludes with information on work done to develop magnesium, copper, and superalloy MMCs.
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
... With an understanding of semisolid metal behavior, several new net-shape manufacturing processes were developed based on closed-die forging, die casting, extrusions, rolling, and hybrids of these processes ( Ref 1 , 2 , 3 ). Since its conception, semisolid metalworking has been applied to numerous metal alloy systems...
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.
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
... strength and toughness achievable with impurity controls. New developments in foundry equipment and control techniques also have helped some foundries to solve the castability problems. Premium-Quality Castings Premium-quality castings provide higher levels of quality and reliability than are found...
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.
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
... had its genesis in Merton Flemings' lab in 1971 with the rheological experiments done by David Spencer as part of his doctoral thesis. The discovery that shearing a semimolten metal produced potentially castable rheologies ignited tremendous interest in what would be an entirely new area of 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: Corrosion: Materials
Series: ASM Handbook
Volume: 13B
Publisher: ASM International
Published: 01 January 2005
DOI: 10.31399/asm.hb.v13b.a0003820
EISBN: 978-1-62708-183-2
... oxide theory, the monovalent magnesium ion theory, the particle undermining model, and the magnesium hydride model ( Ref 1 ). Understanding the actual mechanism may lead to corrosion prevention methods in new magnesium alloys. Galvanic corrosion plagues magnesium alloys. The origin of the problem...
Abstract
This article begins with a discussion on the environmental factors that induce corrosion in magnesium alloys. It reviews the factors that determine the severity of different forms of localized corrosion, namely, galvanic corrosion, corrosion fatigue, and stress-corrosion. The article discusses corrosion protection in magnesium assemblies and the protective coating systems used in corrosion protection practices. Protection schemes for specific applications and the production of novel magnesium alloys with improved corrosion resistance are also reviewed. The article concludes with a discussion on the corrosion of bulk vapor-deposited alloys and magnesium-matrix composites.
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 December 1998
DOI: 10.31399/asm.hb.mhde2.a0003172
EISBN: 978-1-62708-199-3
... Horizontal centrifugal casting Hybrid processes Squeeze casting Semisolid metal casting (rheocasting) (a) When sand or plaster complex cores are used instead of metal cores, the term semipermanent mold casting should be used. Of the expendable mold/permanent pattern processes...
Abstract
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.
Series: ASM Handbook
Volume: 2A
Publisher: ASM International
Published: 30 November 2018
DOI: 10.31399/asm.hb.v02a.a0006488
EISBN: 978-1-62708-207-5
... is called rheocasting. The slurry can also be mixed with particulates, whiskers, or short fibers before casting. This modified form of rheocasting to produce near-net shape MMC parts is called compocasting. Particles and discontinuous fibers of silicon carbide, titanium carbide, alumina, silicon nitride...
Abstract
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.
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005331
EISBN: 978-1-62708-187-0
... ALUMINUM CASTINGS have played an integral role in the growth of the aluminum industry since its inception in the late 19th century. The first commercial aluminum products were castings, such as cooking utensils and decorative parts, which exploited the novelty and utility of the new metal. Those early...
Abstract
This article begins with a discussion on the effects of alloying and impurity elements on the properties of aluminum cast alloys and their chemical compositions. It describes the various means of structural control, namely, chemistry control, control of element ratios based on the stoichiometry of intermetallic phases, and control of solidification conditions. The article discusses the modification and grain refinement of aluminum-silicon alloys by the use of modifiers and refiners to influence eutectic and hypereutectic structures in aluminum-silicon alloys. It provides information on foundry alloys for specific casting applications. The article concludes with a discussion on the heat treatment practices and properties of aluminum casting alloys.
Book Chapter
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005287
EISBN: 978-1-62708-187-0
..., and semisolid forming based on rheocasting/thixocasting principles. Of these casting methods, high-pressure die casting of aluminum is the dominant nonferrous casting process ( Fig. 1 ). Fig. 1 Nonferrous casting processes by tons poured. Source: From data of AFS 2002 survey. This article provides...
Abstract
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.
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
... include molding and pattern distinctions such as lost foam (evaporative pattern), shell and V-mold, and process derivatives such as squeeze casting, low-pressure permanent mold, vacuum riserless casting, and semisolid forming based on rheocasting/thixocasting principles. Of these casting methods, high...
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 Chapter
Series: ASM Handbook
Volume: 18
Publisher: ASM International
Published: 31 December 2017
DOI: 10.31399/asm.hb.v18.a0006412
EISBN: 978-1-62708-192-4
Abstract
A sliding bearing (plain bearing) is a machine element designed to transmit loads or reaction forces to a shaft that rotates relative to the bearing. This article discusses the properties of bearing materials. It provides information on bearing material systems: single-metal systems, bimetal systems, and trimetal systems. The article describes the designations, nominal compositions, mechanical properties, and applications of various sliding bearing alloys: tin-base alloys, lead-base alloys, copper-base alloys, aluminum-base alloys, silver-base alloys, zinc-base alloys, additional metallic materials, nonmetallic materials. It describes casting processes, powder metallurgy processes, and electroplating processes. The article also discusses the selection criteria for bearing materials.
Series: ASM Handbook
Volume: 18
Publisher: ASM International
Published: 31 December 2017
DOI: 10.31399/asm.hb.v18.a0006388
EISBN: 978-1-62708-192-4
..., on the contrary, high-pressure die casting makes it possible to obtain very fine microstructures. Semisolid techniques (e.g., rheocasting, thixocasting, etc.), on the other hand, even though less widespread, allow the production of casting components with very low defect contents. The most common deformation...
Abstract
This article begins by describing the designations of cast and wrought aluminum alloys. It explains the effects of main alloying elements in aluminum alloys: boron, chromium, copper, iron, lithium, magnesium, manganese, nickel, phosphorus, silicon, sodium, strontium, titanium, and zinc. The article describes the microstructure of cast and wrought aluminum alloys and the various strengthening mechanisms, including solid solution, grain refinement, strain or work hardening, precipitation (or age) hardening, and dispersoid strengthening. The article explicates the tribological behavior of aluminum alloys, aluminum-base composites, and metal-matrix composites. It presents the effect of material-related parameters and external factors on wear behavior and transitions of aluminum-silicon alloys. The article also presents the most important factors affecting the dry sliding wear behavior of particle-reinforced aluminum-base composites against a steel counterface.
Book Chapter
Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0009015
EISBN: 978-1-62708-187-0
... Nonferrous and MMCs 1 No Small to medium … Semisolid processing Thixocasting (billet) Aluminum 4 No Small to medium Outstanding Rheocasting (slurry) Nonferrous 5 No Small to medium Outstanding Thixomolding (granular magnesium) Magnesium 5 No Small Outstanding...
Abstract
This article provides a general introduction on casting processes and design techniques. It discusses the process steps and methods of the main categories of shape casting methods, namely, expendable molds with permanent patterns, expendable molds with expendable patterns, and metal or permanent mold processes. The article lists the general guidelines of geometry in casting design. It describes the three separate contractions that are a result of cooling: liquid-liquid contraction, solid-solid contraction, and liquid-solid contraction. Factors influencing the solidification sequence of simple shapes, such as T-sections, X-sections, and L-sections, are discussed. The article also presents an overview of geometric factors that influence heat transfer and transport phenomena. It concludes with a description of the structure and properties of castings.
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 November 1995
DOI: 10.31399/asm.hb.emde.a0003005
EISBN: 978-1-62708-200-6
... products has increased dramatically, and the need for materials that are stronger, lighter, and/or more resistant to corrosion, wear, or heat has prompted tremendous advances in materials science. New materials or enhanced properties of existing materials have also resulted from improvements...
Abstract
The selection of engineered materials is an integrated process that requires an understanding of the interaction between materials properties, manufacturing characteristics, design considerations, and the total life cycle of the product. This article classifies various engineered materials, including ferrous alloys, nonferrous alloys, ceramics, cermets and cemented carbides, engineering plastics, polymer-matrix composites, metal-matrix composites, ceramic-matrix and carbon-carbon composites, and reviews their general property characteristics and applications. It describes the synergy between the elements of the materials selection process and presents a general comparison of material properties. Finally, the article provides a short note on computer aided materials selection systems, which help in proper archiving of materials selection decisions for future reference.
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 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.
Book: Composites
Series: ASM Handbook
Volume: 21
Publisher: ASM International
Published: 01 January 2001
DOI: 10.31399/asm.hb.v21.a0003448
EISBN: 978-1-62708-195-5
... , and 8 ). Semisolid casting methods, such as rheocasting, involve adding the reinforcement to the alloy in a semisolid state. Liquid metal infiltration involves infiltrating a porous preform (the reinforcement) with the molten matrix alloy. The preform can consist of either discontinuous (powders...
Abstract
Metal-matrix composites (MMCs) are used in structural applications, and in applications requiring wear resistance, thermal management, and weight savings. This article summarizes the mechanical and thermal properties of discontinuously reinforced aluminum MMCs, laminated metallic composites, and continuously aligned fiber reinforced MMCs.
Series: ASM Desk Editions
Publisher: ASM International
Published: 01 December 1998
DOI: 10.31399/asm.hb.mhde2.9781627081993
EISBN: 978-1-62708-199-3