Failure analysis of die casting pins for an aluminum engine block

Kang, Se-Hyung; Han, Jaejoon; Hwang, Won-Tae; Lee, Sang‐Min; Kim, Ho-Kyung

doi:10.1016/j.engfailanal.2019.06.053

Cited by 7 publications

(3 citation statements)

References 19 publications

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“…The consequence of this examination uncovers that cooling holes at the center point of the pin were machined with some level of unusualness, prompting a centralization of the thermal stress on the thin part and, at last bringing about a premature failure. Proper machining of a cooling opening in the pass on pins should be completed to keep away from premature failure of these parts [10].…”

Section: Literature Review and Problem Statementmentioning

confidence: 99%

Numerical investigation on crack analysis of H13 fixed die and structural analysis of moving die with two different materials

Abdulhadi

2021

EEJET

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Die casting is forcing molten metal into a mould with high pressure. Die casting has two dies namely moving die and fixed die where the moving one will move over the fixed die. Die casting is majorly used for high-volume production. This paper focused on the physical phenomenon of die casting for two dies (moving die and fixed die) using two different alloy materials with variable material chemical compositions. The numerical analysis is carried out for the die casting process to determine the crack formation zone by temperature distribution and structural analysis by stress-strain relationship. The numerical analysis is carried out for both the dies. The fixed die is analyzed with an H13 tool steel material with two moving die materials as aluminum alloy (A356) and magnesium alloy (AZ91D). Both the dies (fixed and moving) were designed by using design software and meshing is carried out followed by analysis using the analysis software. The physical parameter for the dies is applied that is temperature distribution is carried out by applying a temperature of 850 °C and 650 °C over the fixed die for aluminum and magnesium alloy, respectively. Structural analysis is carried out for the moving die with a load of 1,000 N for both aluminum and magnesium alloys with 1000 number of iterations. The results from the numerical analysis are derived and analyzed for both temperature distribution and structural analysis. The crack formation zone is found out by means of temperature gradient and the stress-strain relationship is found out by means of structural analysis. From the results, it was concluded that the crack zone is obtained at 1.22E-10 °C/mm and 6.856E-14 °C/mm of thermal gradient and structural analysis in terms of maximum stress of 446.94 MPa and 448.52 MPa for aluminum and magnesium alloys, respectively.

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Section: Literature Review and Problem Statementmentioning

confidence: 99%

Numerical investigation on crack analysis of H13 fixed die and structural analysis of moving die with two different materials

Abdulhadi

2021

EEJET

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“…The molten metal is then stirred continuously. (6) After melting the aluminium scrap and making all the moulds, the molten metal was then poured into the moulds using a small steel plate held with a tong. Ten moulds were made in a canoeshaped form and one mould was shapeless.…”

Section: Melting and Casting Of The Aluminium Scraps (1)mentioning

confidence: 99%

“…In automobile engineering in developing countries, the general practice is to dispose of out-of-use engine blocks and parts and such practices often lead to environmental pollution due to the reactions of the metallic parts with soils in the long-run, and the contamination of soils with engine oil remnants from the engine blocks [5]. Engine block re-use can be made in a melting and solidification process for new product formation in a casting process, particularly in foundry systems wherewith the A356 alloy matrix may be complemented with reinforcements for enhanced corrosion, wear and mechanical properties [6][7][8][9]. This means that A356 alloy auto-parts, which are often disposed of as wastes have strong potentials to be transformed into new, exciting, useful and innovative engineering products such as the tyre wheel cover, among others, as the A356 alloy is infused with organic reinforcements.…”

Section: Introductionmentioning

confidence: 99%

Taguchi Optimisation of Cast Geometries for A356/Organic Particulate Aluminium Alloy Composites Using a Two-Phase Casting Process

Nwafor

Oke

Ayanladun

2019

JASPE

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The A356 alloy is widely known to exhibit an extremely superior casting, machining, mechanical, and corrosion resistance properties. Despite these, it constitutes an environmental nuisance at its improper disposal for worn-out engine blocks. Also, organic reinforcements have the potentials to reduce the environmental impacts of composites. Consequently, there exits significant research potential to fuse A356 alloy with organic materials to obtain enhanced composite properties. In the area of aluminium matrix, as melting and solidifications of materials are done the accuracy of measurements is driven by the huge array of process parameters and the geometrical aspect of cast components is important. For these reasons, we attempt to solve the problem of optimising the geometry of casts in a complicated scenario with the use of the robust Taguchi's methods. To optimise the framework, the significant process parameters are identified and their effects studied in a route using Taguchi, Taguchi-Pareto and Taguchi–ABC methods. Parameters such as the volume of the cast, length, weight, density, height, width, breadth, weight loss and the total weight of organic materials infused into the melting process were studied for parametric changes, interactions and optimisation with L27 orthogonal array. The analysis of variance for the A356 alloy cast revealed that the density parameter of cast 1 had the highest and major significant effect on the casting process with a variance of 333573, followed by weight parameter of casts 1 and 2, total weight of organic material parameters and weight loss with the variance values of 0.007, 0.005, 0.001 and 0.004, respectively. The variance of other parameters was insignificant to the A356 alloy cast.

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Rice husk-extracted silica reinforced graphite/aluminium matrix hybrid composite

Saini

Gupta

Mehta

et al. 2020

J Therm Anal Calorim

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Failure analysis of die casting pins for an aluminum engine block

Cited by 7 publications

References 19 publications

Numerical investigation on crack analysis of H13 fixed die and structural analysis of moving die with two different materials

Numerical investigation on crack analysis of H13 fixed die and structural analysis of moving die with two different materials

Taguchi Optimisation of Cast Geometries for A356/Organic Particulate Aluminium Alloy Composites Using a Two-Phase Casting Process

Rice husk-extracted silica reinforced graphite/aluminium matrix hybrid composite

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