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PROCESS PARAMETERS OF AL ALLOY CASTINGS PRODUCED BY HIGH PRESSURE DIE CASTING

Author: Dharmpal Deepak

Publisher: BookRix

Published: 2019-09-16

Total Pages: 76

ISBN-13: 3748715587

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.

Advanced Materials in Automotive Engineering

Author: Jason Rowe

Publisher: Elsevier

Published: 2012-02-21

Total Pages: 353

ISBN-13: 0857095463

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The automotive industry is under constant pressure to design vehicles capable of meeting increasingly demanding challenges such as improved fuel economy, enhanced safety and effective emission control. Drawing on the knowledge of leading experts, Advanced materials in automotive engineering explores the development, potential and impact of using such materials.Beginning with a comprehensive introduction to advanced materials for vehicle lightweighting and automotive applications, Advanced materials in automotive engineering goes on to consider nanostructured steel for automotive body structures, aluminium sheet and high pressure die-cast aluminium alloys for automotive applications, magnesium alloys for lightweight powertrains and automotive bodies, and polymer and composite moulding technologies. The final chapters then consider a range of design and manufacturing issues that need to be addressed when working with advanced materials, including the design of advanced automotive body structures and closures, technologies for reducing noise, vibration and harshness, joining systems, and the recycling of automotive materials.With its distinguished editor and international team of contributors, Advanced materials in automotive engineering is an invaluable guide for all those involved in the engineering, design or analysis of motor vehicle bodies and components, as well as all students of automotive design and engineering. Explores the development, potential and impact of using advanced materials for improved fuel economy, enhanced safety and effective mission control in the automotive industry Provides a comprehensive introduction to advanced materials for vehicle lightweighting and automotive applications Covers a range of design ideas and manufacturing issues that arise when working with advanced materials, including technologies for reducing noise, vibration and harshness, and the recycling of automotive materials

High Integrity Die Casting Processes

Author: Edward J. Vinarcik

Publisher: John Wiley & Sons

Published: 2002-10-16

Total Pages: 253

ISBN-13: 0471275468

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"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.

Casting Aluminum Alloys

Author: Michael V Glazoff

Publisher: Elsevier

Published: 2010-07-07

Total Pages: 544

ISBN-13: 9780080550237

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Casting Aluminum Alloys summarizes research conducted at Moscow Institute of Steel and Alloy during many decades in part together with Alcoa Inc. The research covered areas of the structure, properties, thermal resistance, corrosion and fatigue of aluminum alloys in industrial manufacturing. Emphasis on interconnection among phase equilibria, thermodynamics and microstructure of alloys Systematic overview of all phase diagrams with Al that are important for the development of casting aluminium alloys Diagrams ("processing windows") of important technological properties such as castability, molten metal fluidity, tendency to hot pre-solidification cracking, porosity Mathematical models for alloy mechanical properties facilitating the down-selection of best prospect candidates for new alloy development New principles of design of eutectic casting aluminium alloys Examples of successful novel casting alloy development, including alloys for high-strength applications, alloys with transition metals, and novel alloys utilizing aluminium scrap

Light Metals 2014

Author: John Grandfield

Publisher: Springer

Published: 2016-12-23

Total Pages: 1406

ISBN-13: 3319481444

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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

Aluminum Alloy Castings

Author: John Gilbert Kaufman

Publisher: ASM International

Published: 2004-01-01

Total Pages: 350

ISBN-13: 0871708035

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

Fundamentals of Aluminium Metallurgy

Author: Roger Lumley

Publisher: Elsevier

Published: 2010-11-25

Total Pages: 862

ISBN-13: 0857090259

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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

Nanotechnologies in Green Chemistry and Environmental Sustainability

Author: Samsul Ariffin Abdul Karim

Publisher: CRC Press

Published: 2022-12-09

Total Pages: 279

ISBN-13: 1000802744

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Presenting latest research on green materials and sustainability. Provide in depth discussion on modeling and simulation using latest techniques. Technical exposure for the readers on additive manufacturing principles. Numerous examples on nanofluids and nano technology are presented. Discusses computer modeling, superconductivity, nanotubes and related structures such as graphene.

Magnesium Technology 2011

Author: Wim Sillekens

Publisher: Springer

Published: 2016-12-10

Total Pages: 649

ISBN-13: 3319482238

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The Magnesium Technology Symposium, which takes place every year at the TMS Annual Meeting & Exhibition, is one of the largest yearly gatherings of magnesium specialists in the world. Papers are presented in all aspects of the field, ranging from primary production to applications to recycling. Moreover, papers explore everything from basic research findings to industrialization. Magnesium Technology 2011 covers a broad spectrum of current topics, including alloys and their properties; cast products and processing; wrought products and processing; forming, joining, and machining; corrosion and surface finishing; ecology; and structural applications. In addition, you'll find coverage of new and emerging applications in such areas as biomedicine and hydrogen storage.

Advances in Manufacturing II

Author: Adam Hamrol

Publisher: Springer

Published: 2019-04-27

Total Pages: 400

ISBN-13: 3030187896

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This book covers a variety of topics in manufacturing, with a special emphasis on product design, production planning, and implementation of both resources and production processes. The content is based on papers presented at the 6th International Scientific Technical Conference MANUFACTURING 2019, held in Poznan, Poland on May 19-22, 2019. The main focus is on showing best practices to use tools currently available in the enterprises to effectively improving industrial processes. Knowledge and production flow management, decision-making systems, production leveling, enterprise efficiency, as well as maintenance, modeling and simulation of production processes are just some of the topics discussed in this book, which offers a timely and practice-oriented reference guide for applied researchers, product engineers and product managers.