Manufacturing Technology for Hollow Structure Large Aluminum Parts Production by High Pressure Die Casting (HPDC)

Advances in Metal Casting Technology: A Review of State of the Art, Challenges and Trends—Part II: Technologies New and Revived

“…Their general feasibility also for larger parts with considerable flow lengths was demonstrated by Koya et al, who considered a hollow casting for application as a motorcycle rear swing arm. Their studies confirmed aspects of the previously cited work by Kohlstädt et al [170][171][172], showing that the impulsive pressure waves that were theoretically predicted and later experimentally confirmed contribute significantly to the loads acting on the core, but they can be alleviated via the adaptation of flow paths and filling conditions, thus opening up a process window for the use of sand cores in large component HPDC [161]. Currently, several suppliers of molding materials, such as Hüttenes-Albertus or Foseco, are taking up this approach and are actively working on or have already presented sand cores suitable for HPDC.…”

“…Since some of these have already been discussed, such as compound casting solutions, where complexity is introduced through an insert, the main focus of the present section will be on cores in general, as well as AM of lost and permanent molds. HPDC 3 Al HPDC process parameter adaptation to limit peak loads of cores, thus facilitating use of sand cores [161] HPDC 3 Al, Mg, Zn Use of sand cores with water-soluble binder and sealant for limited complexity undercuts and hollow sections [162] HPDC 3 Al, Mg, Zn Multi-plate die technology to optimize flow paths, thus facilitating increased part complexity [163] HPDC 3 Al, Mg Switch from conventional HPDC to semi-solid processing for increased flow paths and lower achievable wall thickness [164] GDC, LPDC, HPDC 3 diverse Implementation of improved heat conduction in dies through multi-material AM approaches [165] GDC, LPDC, HPDC 3 diverse Implementation of conformal cooling via AM of a die insert for HPDC of a Zn alloy [166,167] diverse diverse…”

Al-Based Foams as Permanent Cores in Al Castings: Effect of Surface Skin Thickness and Composition on Infiltration and Core-Shell Bonding

“…Moreover, the aluminum realization of hollow structures has been investigated for weight reduction by using sand cores [2]. However, this approach requires complex process design and can often lead to critical conditions in term of resistance.…”