Performance Evaluation of Different Air Venting Methods on High Pressure Aluminum Die Casting Process

Altuncu, Ekrem; Doğan, Ayşegül; Ekmen, N.

doi:10.12693/aphyspola.135.664

Cited by 2 publications

(1 citation statement)

References 6 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The main causes of the gas porosity can be found in the gas entrapment of the melt in the filling chamber of the machine, in the poor gate design, in the turbulent flow of the melt in the mold cavity and in incorrect design of the mold overflow system. Some secondary causes are coolant leakage into the mold, excess lubricant and the mold spraying [9][10][11].…”

Section: Introductionmentioning

confidence: 99%

Archives of Foundry Engineering

Majerník,

Podařil,

Gojdan

2020

View full text Add to dashboard Cite

High pressure die casting technology (HPDC) is a method enabling the production of shape-complex casts with good mechanical properties, with high repeatability of production within narrow tolerance limits. However, the casts show, to some extent, basic porosity, which may reduce their mechanical and qualitative properties. One of the main areas to focus on in order to reduce the porosity of casts is the correct design and structure of the gating and overflow system. Submitted article is devoted to the assessment of the connecting channel cross-section design for connecting the overflows to the cast on selected parameters of the casting process. Five different crosssection designs of connecting channels are considered, enabling the removal of gases and vapors from the volume during the molding. The connecting channels are designed with a constant width g = 10mm and variable height h1 = 1.50 mm, h2 = 1.25 mm, h3 = 1.00 mm, h4 = 0.75 mm and h5 = 0.6 mm. The primary monitored parameter is the gas entrapment in selected points of the cast. The following is an evaluation of the pressure conditions change in the mold cavity at the end of the filling mode and local overheating of the mold material just below the surface of the mold face. With regard to the monitored parameters, based on the performed analyzes, the most suitable design solution of the connecting channel is assessed and recommendations for the design and structure of the overflows and their connection to the cast are derived.

show abstract

Section: Introductionmentioning

confidence: 99%

Archives of Foundry Engineering

Majerník,

Podařil,

Gojdan

2020

View full text Add to dashboard Cite

show abstract

Viability of Flax Fiber-Reinforced Salt Cores for Aluminum High-Pressure Die Casting in Experiment and Simulation

Boos,

Zaremba,

Drechsler

2024

Inter Metalcast

View full text Add to dashboard Cite

Parts with undercuts or hollow sections exploit the maximum lightweight potential due to efficient material usage. However, such geometries are often challenging to produce with ordinary tooling technology, especially in aluminum high-pressure die casting (HPDC). In order to close this gap, this paper investigates flax fiber-reinforced salt made by wet compression molding as a new lost core material that can be removed with water. Three-point bending tests and HPDC experiments characterized the material. The 2D and 3D simulations with aluminum melt and compressible air were carried out in ANSYS Fluent 2023R1. The outlet vent boundary condition is characterized separately to address the geometric features of the outlet vent. Combined with a two-phase flow filling simulation, it allows assessing the actual loads on the lost core material. The simulations show an excellent agreement between the proposed one-dimensional, analytical outlet model and the computational fluid dynamics (CFD) results. The 2D filling simulations are helpful to prove mesh convergence and model simplifications but overestimate the loads. A 3D simulation predicts stress peaks up to 33 MPa for an ingate speed of 64 m/s. Conventional, brittle salt cores with a bending strength of 15 MPa fail under these conditions in the HPDC experiment. In contrast, fiber-reinforced salt cores with bending strengths between 11 and 37 MPa are viable thanks to their toughness, which was demonstrated by a eight to 31 times higher energy absorption than the unreinforced benchmark in the three-point bending tests. With the new robust lost core material, a foundry gains a technology advantage that opens up new markets, e.g., in the mobility sector.

show abstract

Performance Evaluation of Different Air Venting Methods on High Pressure Aluminum Die Casting Process

Cited by 2 publications

References 6 publications

Archives of Foundry Engineering

Archives of Foundry Engineering

Viability of Flax Fiber-Reinforced Salt Cores for Aluminum High-Pressure Die Casting in Experiment and Simulation

Contact Info

Product

Resources

About