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Casting is one of the most economical manufacturing processes for providing shape to components of machinery, and it covers a wide range of industries. It has evolved over many centuries, from being depicted in artwork dating back to 4000 B.C., to being used in the most demanding structural applications of today, such as the aerospace and automotive industries. Aluminum has proven to be the material of choice, for strength, durability, styling and recycling, for various applications. It has successfully replaced iron and steel over the years, bringing economic and environmental benefits to many industries.

The Aluminum Castings Engineering Guide is a compilation of years of engineering and practical experience in the manufacture of millions of aluminum castings of the highest integrity in the industry.

This book offers a structured approach to linking the two basic needs of functionality and manufacturability. Product designers can benefit from the knowledge of casting processes and materials, and casting process engineers can benefit from a rational approach to developing configurations that are manufacturable, economical, and competitive.

Extensive examples and practical guidelines illustrate the principles and proven practices. The tables present concise information that can be used for ready reference.

The book presents:

  • Simultaneous engineering for the most optimal and cost-competitive product configurations

  • Overview of casting processes including green sand, air set or nobake molding, vacuum molding, evaporative foam casting, gravity permanent molding, counter pressure casting, squeeze casting, investment casting, rapid prototype casting, cast-forge hybrid, and semi-solid metal process

  • Best process and alloy selection guidelines for products

  • Die casting engineering and gating options

  • Detailed descriptions and illustrations of gravity permanent mold casting—tooling, feeding, and gating engineering

  • Detailed descriptions and illustrations of low-pressure permanent mold casting—pioneering concepts for engineering castings of the highest quality in the industry

  • Typical product specifications, and

  • Product launches for successful manufacturing

The application of finite element analysis and 3D printing in the design of castings and prototype manufacturing is also discussed.

Product design engineers, casting manufacturing engineers, casting buyers, foundry personnel in the aluminum casting field, and students specializing in casting technology will find this guide very useful and practical.

Jagan Nath

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