High Pressure Die Casting

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.

"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.

The Light Metals symposia are a key part of the TMS Annual Meeting & Exhibition, presenting the most recent developments, discoveries, and practices in primary aluminum science and technology. Publishing the proceedings from these important symposia, the Light Metals volume has become the definitive reference in the field of aluminum production and related light metal technologies. The 2014 collection includes papers from the following symposia: •Alumina and Bauxite •Aluminum Alloys: Fabrication, Characterization and Applications •Aluminum Processing •Aluminum Reduction Technology •Cast Shop for Aluminum Production •Electrode Technology for Aluminum Production •Light-metal Matrix (Nano)-composites

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

Aluminium is an important metal in manufacturing, due to its versatile properties and the many applications of both the processed metal and its alloys in different industries. Fundamentals of aluminium metallurgy provides a comprehensive overview of the production, properties and processing of aluminium, and its applications in manufacturing industries. Part one discusses different methods of producing and casting aluminium, covering areas such as casting of alloys, quality issues and specific production methods such as high-pressure diecasting. The metallurgical properties of aluminium and its alloys are reviewed in Part two, with chapters on such topics as hardening, precipitation processes and solute partitioning and clustering, as well as properties such as fracture resistance. Finally, Part three includes chapters on joining, laser sintering and other methods of processing aluminium, and its applications in particular areas of industry such as aerospace. With its distinguished editor and team of expert contributors, Fundamentals of aluminium metallurgy is a standard reference for researchers in metallurgy, as well as all those involved in the manufacture and use of aluminium products. Provides a comprehensive overview of the production, properties and processing of aluminium, and its applications in manufacturing industries Considers many issues of central importance in aluminium production and utilization considering quality issues and design for fatigue growth resistance Metallurgical properties of aluminium and its alloys are further explored with particular reference to work hardening and applications of industrial alloys

For a long time, the die cast industry has used trial and error as a leading development method, resulting in tremendous growth in the utilisation of available CFD (computational fluid dynamics) software. This software allows the development of better products that maximise the advantages the die cast process has to offer. Casting: An Analytical Approach will refresh knowledge of the governing laws of the fluid dynamics that have an effect on die cast die and die cast process design. MATLAB® (MathWorks, Inc.) and Visual Basic® (Microsoft) code are listed in Casting: An Analytical Approach for every stage of product, die and die cast process design; providing better understanding of die and process design and simplifying calculations of the die cast die as well as the die cast process. Gas ventilation system calculations and fundamentals of compressible gas flow are also included. Readers will learn about: the advantages and limitations of the die cast process; the implications that product design has on the quality of the die cast part; how die cast die and process design can affect the physical properties of the casting; the calculations die cast die and process designers have to do; choosing the die cast machine size and the proper gate size; and how to properly design gas ventilation systems, identify an ideal fill time, and calculate fast and slow shot velocity. The use of MATLAB® and Visual Basic® code to illustrate every stage of the design will help readers to gain a better understanding of the importance of collaboration throughout the entire process. Therefore, Casting: An Analytical Approach will be of interest to product designers who design die cast parts, and die cast die and process engineers and designers.