Experimental and Theoretical Studies on the Effect of Die Temperature on the Quality of the Products in High-Pressure Die-Casting Process

Sadeghi, Mohammad; Mahmoudi, Jafar

doi:10.1155/2012/434605

Cited by 17 publications

(13 citation statements)

References 14 publications

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“…These include agglomeration of the nano-size reinforcement in the matrix [10][11][12], grain growth of the matrix [13,14], poor interfacial bonding [9,13], and high cost [9]. Liquid-state processing techniques suffer from the poor wettability of the reinforcement with the liquid matrix [15][16][17][18][19]. In addition, they may lead to the formation of unwanted and brittle phases like Al4C3 and Si, in the case of Al-SiC composites [16,20], due to processing at relatively high temperatures.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Properties of Spark Plasma Sintered Aluminum Containing 1 wt.% SiC Nanoparticles

Aliyu

Saheb²,

Hassan³

et al. 2015

Metals

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Abstract:The low hardness and strength of aluminum, which limits its use in many industrial applications, could be increased through the addition of nanoparticles. However, the appropriate processing method and parameters should be carefully selected in order to achieve the desired improvement in properties. In this work, aluminum was reinforced with low weight fraction (1 wt.%) of SiC nanoparticles and consolidated through spark plasma sintering. The effect of processing parameters on the densification, microstructure, and properties of the processed material was investigated. Field Emission Scanning Electron Microscope (FE-SEM) equipped with Energy Dispersive X-ray Spectroscopy (EDS) facility was used to characterize the microstructure and analyze the reinforcement's distribution in sintered samples. Phases present were characterized through X-ray diffraction (XRD). A densimeter and a digital microhardness tester were used to measure the density and hardness, respectively. Compressive tests were performed using universal testing machine. A fully dense Al-1 wt.% SiC sample was obtained. Analysis of density and hardness values showed that the influence of applied pressure was more pronounced than heating rate while the influence of sintering temperature was more significant than sintering time. Within the range of parameters used, the highest values of the characterized properties were obtained at a sintering temperature of 600 °C, sintering time of 10 min, pressure of 50 MPa, and heating rate of 200 °C/min. OPEN ACCESSMetals 2015, 5 71

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Section: Introductionmentioning

confidence: 99%

Microstructure and Properties of Spark Plasma Sintered Aluminum Containing 1 wt.% SiC Nanoparticles

Aliyu

Saheb²,

Hassan³

et al. 2015

Metals

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“…In the paper by Mohammad Sadeghi, etal [1] , die temperature in high-pressure die casting of A380 alloy is optimized by experimental observation and numerical simulation. Ladder frame (one part of the new motor EF7) with a very complicated geometry was chosen as an experimental sample.…”

Section: Literature Reviewmentioning

confidence: 99%

Temperature Defects on Compressor Housing Die Casting Method

Prasad¹

2017

International Advanced Research Journal in Science, Engineering

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Abstract:With the increasing power of computer hardware and software, computational simulation and visualization are becoming increasingly important tools to understand and improve industrial processes, such as metal casting. Computer-aided visualization is increasing the power of all of the tools available to the solidification process engineer, including previous literature, mathematical modeling, laboratory experimentation, and online measurement of the casting processes. Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. In this thesis, main emphasis will be on the optimization of process parameters in High pressure die casting. A case study of compressor housing is considered where the flow simulations results are analyzed for optimization. An analytical approach is discussed by using software Ansys Fluent to analyze the behavior of molten metal at different stages of time by observing the results of temperature variations, pressure variations and liquid fractions by applying the input parameters molten metal temperature, die temperature and velocity of flow. The model of the component with spreader design, runner design, gate location and overflows is done in 3D modeling software Pro/Engineer.

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“…In [18], it is stated that surface defects are correlated to the heat transfer coefficient between the alloy and the die, which depends on oxidation and turbulence. In [19], the defects are shown to occur below a threshold of the die surface temperature. In [20], tests with different injection temperatures indicate that the formation of a slurry of dendrites (mushy solidification) cause long-freezing alloys to be less prone to cold flow defects; for short-freezing alloys, the criticality seems to depend on the thickness of the early solidified layers (with a possible threshold of approximately 0.2 mm).…”

Section: Background and Literaturementioning

confidence: 99%

Cold flow defects in zinc die casting: prevention criteria using simulation and experimental investigations

Armillotta

Fasoli²,

Guarinoni

2015

Int J Adv Manuf Technol

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High-pressure die casting of zinc alloys is increasingly used in the manufacturing of parts with high aesthetic value. These parts must comply with strict requirements on surface quality, which are generally overlooked in traditional mechanical applications. Cold flow defects, which are a primary concern for surface quality, originate from several different causes that have not yet been fully understood. This report investigates the factors that influence cold flow defects and the choices that can lead to an improvement in surface quality. The research method is based on a case study performed at a die casting company. First, an existing process has been analyzed using simulation to explain the causes of cold flow defects observed in production samples. The temperature at the end of the cavity fill has emerged as a key index for the occurrence of defects, which can be controlled by three primary process parameters: injection velocity, temperature of the cooling medium, and lubricant spraying time. These same factors are then assessed using experimental tests on an existing die, where the number of defects in the selected regions of the casting has been evaluated by image processing. The results suggest that the surface quality can be particularly improved by increasing the flow rate of the molten metal through the gates and avoiding excessive flow turbulence in the wide cavity sections. Consequently, the increase in the gate area has been identified as a specific criterion for the die design. These findings have been validated in the redesign of the die and the selection of the process parameters, which have resulted in a significant reduction in the surface defects.

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Experimental and Theoretical Studies on the Effect of Die Temperature on the Quality of the Products in High-Pressure Die-Casting Process

Cited by 17 publications

References 14 publications

Microstructure and Properties of Spark Plasma Sintered Aluminum Containing 1 wt.% SiC Nanoparticles

Microstructure and Properties of Spark Plasma Sintered Aluminum Containing 1 wt.% SiC Nanoparticles

Temperature Defects on Compressor Housing Die Casting Method

Cold flow defects in zinc die casting: prevention criteria using simulation and experimental investigations

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