Die Casting

"It's about time that a practicing engineer with casting and academic experience has written a book that provides answers to questions about squeeze casting and semi-solid molding/forming that many engineers and students of casting need answered." —Joseph C. Benedyk, PhD, Consultant and retired technical director, Alcoa High Integrity Die Casting Processes provides a comprehensive look at the concepts behind advanced die casting technologies, including vacuum die casting, squeeze casting, and several variants of semi-solid metalworking. Practical applications for these processes are illustrated in numerous case studies. This single-source reference tool presents the latest material in five sections: Basic concepts of die casting and molten metal flow High integrity die casting processes with case studies Product design considerations Controlling quality and avoiding defects Future advances under development Key coverage includes a survey of liquid metal flow, strategies to overcome the limitations of conventional die casting, and potential defects unique to high integrity die casting processes. Also featured are methods for minimizing porosity, reducing cost by design, practical applied statistical process control techniques, designing for manufacturability, and containment methods for potential processing defects. Several chapters present detailed real-world examples illustrating the broad range of applications possible using high integrity die casting processes. Included with this book is a CD-ROM containing PowerPoint(r) presentations for each chapter. These presentations can be used for training purposes in conjunction with numerous study questions designed to practically apply the content of the book to real-world situations. Selected PowerPoint(r) slides can be used to support engineering proposals, marketing presentations, or customer education seminars. High Integrity Die Casting Processes is a valuable reference for both component producers and component users alike. Process engineers, tool designers, manufacturing engineers, production managers, and machine operators will acquire a better understanding of these advanced die casting processes to optimize manufacturing and improve product quality. Component designers, product engineers, purchasing agents, buyers, supplier quality engineers, and project managers will gain insight into these processes and develop superior products by design.

Die Casting Metallurgy focuses on developments in the metallurgy of die casting. Ore distribution, smelting methods, and energy requirements for the major non-ferrous metals that are die cast are considered. This text has 29 chapters; the first of which provides an overview of early developments in die casting. After explaining how metals and alloys are die cast, the book turns to the production of aluminum and its alloys, aluminum alloy die castings, and melting equipment for aluminum alloys. The chapters that follow explore the metallurgy of zinc and magnesium alloys; brass and ferrous die casting; automatic metal transfer systems; metal melting treatments; and the metallurgy of die casting machines. Developments in lubrication, die casting, and finishing processes are also considered. This book also describes pressure die casting dies, thermal fatigue of die casting dies, heat treatment of die steels, and surface treatment of steels. Some comparative alloy specifications are summarized and an attempt is made to correlate units of hardness, strength, and other properties. This book will be of interest to materials scientists and industrial materials engineers.

Hello, my friends, I hope you all are safe and sound. As we all know the pandemic effect is now about to finish. We all are back to our professional life with full of passion and energy. Currently, I have been working in the M/S Castomach Global Pvt. Ltd. located in Chakan, Pune. I am working as an R & D manager. Castomach is a manufacturer of finished PDC parts for reputed automotive and non-automotive companies such as LUCAS- TVS, Valeo, Varroc, Atomberg etc. My native place is Kevanale in Raigad district Maharashtra. I have worked in medium-scale companies as a Quality Manager, Production Head, Development head, maintenance dept, etc. I have been working in the industry for 25+ years. As an engineer, we face every day different challenges. In simple words, we have to give an exam every day and we have to win it with distinction marks. The interesting thing is that we get different kinds of questions while working in the industry which we have to solve with our expertise and knowledge. Many times, certain technical/quality issues may seem to be difficult to tackle. Working in this industry for 25+ years’ experience I can say “nothing is impossible.” I also felt at a certain point, that I should share my technical knowledge and expertise with all our Technocrat friends, because “knowledge sharing is knowledge gaining”. This book will also help to understand college students of Mechanical Engineering as well as to our Technocrat friends about pressure die casting and its related process and details about various metals and technical content about the PDC. I would like to express my gratitude towards our honourable directors Mr.Tushar Bafna, Mr.Anup Saklecha, Mr.Balu Jogdand sir. Without their support, it was difficult for me to write my experience on paper. I would also like to mention the name of our Plant Head Mr.Omkar Gangdhar and all the technical teams working in the Castomach. Their support is very much commendable. I would like to honour Mr.Nityanand Choudhari sir Technical Director from Alcast Foundry Pvt. Ltd. I would also like to honour Mr. Ashwin Shah sir and Mr. Ajit sir from Matchwell die-casters where I worked under them for many years. This book will help you to know the details about the PDC process, raw material details, technical details, machine details etc. Lastly, I hope the book will enrich the knowledge of die casting in all my technocrat friends as well as it will guide the Mechanical Engineering students from all the universities. I am waiting to hear feedback from all my friends. Thank you. Suresh Sonawane.

A frequently misunderstood technology, die casting is considered the shortest route between raw material and near net shape. For many decades, high pressure die casting was viewed as an art based upon "seat of the pant" strategies. However, many of these crude reactions actually worked because the fundamental process is quite forgiving of eccentric

This monograph provides a field-proven approach to analyze industrial production with a cross-company scope as well as regarding all hierarchical system levels of manufacturing enterprises. The book exemplifies this approach in the context of aluminum die casting, and presents a set of measures which allow a 30 percent energy reduction along the value chain. The target audience primarily comprises researchers and experts in the field but the book may also be beneficial for graduate students.

This book presents a study on the influence of selected technological parameters of die casting upon strength and use properties of Al-Si alloy casts produced in die casting. It contains a theoretical part describing the principles of casting technology, and its practical part revolves around the relationship between selected technological parameters of die casting in regard to strength and use properties represented by tensile strength and porosity of die casts.

In the current study, an industrial product (electrical wire connector) have been casted in cold chamber die casting process using LM2 aluminium alloy to produce certain specimens to be assessed under the study for the determination of the responses ( mechanical properties such as impact strength, hardness and surface roughness). As cold chamber die casting is being popularly known for its efficient and accurate casting process which can process a broad range of castings with intricate shape easily, hence it requires a lot of study in controlling the process variables with optimum combination of process variables to produce defect free and sound casting. Therefore in the current study, the process variables such as pouring temperature (725oC, 750oC, 775oC), intensification pressure (170 kg/cm2, 180 kg/cm2, 190 kg/cm2), type of coating (oil+graphite coating, dycote+graphite coating and dycote coating) and type of cooling (air cooling, water cooling and oil cooling) have been varied at three levels and 9 different experiments have been designed using Taguchi array (L9 orthogonal array) to assess the effects of different combinations of process variables over the mechanical properties (impact strength, hardness and surface roughness). The study aims at selecting the optimum combination process variables on the basis of the responses resulted in the 9 experiments. The graphs for the responses (impact strength, hardness and surface roughness) against each process variables have been plotted and carefully observed to identify the significant process variable along with respective level of operation affecting the respective response. From the overall study, intensification pressure was concluded to be the most significant process variable with maximum contribution to the impact strength and surface finish. The micrograph images captured corresponding to the respective levels of intensification pressure (170 kg/cm2, 180 kg/cm2, 190 kg/cm2) revealed the presence of shrinkage porosity corresponding to lowest level of intensification pressure (170 kg/cm2) and with further increase in intensification pressure led to a decrease in the extent of presence of porosity. Dycote coating was considered as the most optimum coating with significant contribution to the hardness. Air cooling and oil cooling were equally significant process variables with equivalent contribution to the mechanical properties.

J. G. (Gil) Kaufman is currently president of his consulting company, Kaufman Associates.