Effects of die shape and injection conditions proposed with numerical integration design on liquid segregation and mechanical properties in semi-solid die casting process

2006 ◽  
Vol 176 (1-3) ◽  
pp. 45-54 ◽  
Author(s):  
P.K. Seo ◽  
D.U. Kim ◽  
C.G. Kang
Keyword(s):  
Mechanical Properties ◽  
Numerical Integration ◽  
Die Casting ◽  
Casting Process ◽  
Liquid Segregation ◽  
Die Casting Process ◽  
Semi Solid

Development of Horizontal Reheating System for Semi-Solid Die Casting and Its Microstructure Evaluation

2005 ◽  
Vol 475-479 ◽  
pp. 377-380
Author(s):  
P.K. Seo ◽  
Byung Min Kim ◽  
Chung Gil Kang
Keyword(s):  
Die Casting ◽  
Casting Process ◽  
Complicated Shape ◽  
Forming Process ◽  
Globular Structure ◽  
Liquid Segregation ◽  
Die Casting Process ◽  
Semi Solid ◽  
Reheating Process ◽  
High Frequency Induction

The parts manufactured by die casting process usually contain liquid segregation and porosities. To solve these problems, the semi-solid forming process has been applied. The process enables material in the semi-solid state to be completely filled, and parts with the complicated shape to be fabricated by applying relatively low pressure. This process is necessary in order to control the microstructure of the billet as well as to achieve the desired semi-solid billet state. In this study, a horizontal high-frequency induction heating device which can be fabricated by semi-solid forming irrespective of a billet's size was developed. A globular structure of the reheated billet and a billet's temperature distribution during the reheating process for A356 were investigated.

Microstructure and Mechanical Properties of Al Alloys by Semi-Solid Processing with LSPSF Technology

2009 ◽  
Vol 628-629 ◽  
pp. 477-482 ◽  
Author(s):  
Hong Min Guo ◽  
Xiang Jie Yang ◽  
J.X. Wang
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloys ◽  
Die Casting ◽  
High Strength ◽  
Casting Process ◽  
Homogeneous Distribution ◽  
Casting Alloy ◽  
Die Casting Process ◽  
Casting Industry ◽  
Semi Solid

Rheoforming is becoming the choice of the casting industry which relies on the semi-solid slurry for high integrity structural parts. The potential of rheoforming with LSPSF (Low superheat pouring with a shear field) for aluminum alloys was investigated in the present work. High quality semi-solid slurries of a series of aluminum alloys were manufactured by LSPSF process, such as casting alloy A356, high strength alloy 201, secondary die casting alloy A380 and wrought alloy 2024, 6082 and 7075, in which the primary α-Al presented spherical, small and homogeneous distribution, especially with zero-entrapped liquid. Applications of LSPSF in high pressure die casting process and squeeze casting process were presented. Results showed that LSPSF rheoforming could improve microstructures and increase mechanical properties.

Development of Semi-Solid Die Casting Product Design and Die Design Technology for Aluminium Alloy Clamp

2016 ◽  
Vol 256 ◽  
pp. 334-339 ◽  
Author(s):  
Song Chen ◽  
Fan Zhang ◽  
You Feng He ◽  
Da Quan Li ◽  
Qiang Zhu
Keyword(s):  
Product Design ◽  
Die Casting ◽  
Casting Process ◽  
Die Design ◽  
Thick Wall ◽  
Thin Wall ◽  
Gating System ◽  
Cross Sectional ◽  
Die Casting Process ◽  
Semi Solid

Semi-solid slurry has significantly higher viscosity than liquid metal. This character of fluidity makes product design and die design, such as gating system, overflow and venting system, be different between these two die casting processes. In the present paper, taking a clamp product as an example, analyses the product optimization and die design by comparing the experimental and computational numerical simulation results. For the clamp, product structure is designed to be suitable for characters of SSM die casting process. The gating system is designed to be uniform variation of thickness, making the cross-sectional area uniformly reduce from the biscuit to the gate. This design ensures semi-solid metal slurry to fill die cavity from thick wall to thin wall. Gate position is designed at the thickest location, the gate shape of semi-solid die casting is set to be much bigger than traditional liquid casting. A good filling behaviour can be achieved by aforementioned all these design principles and it will be helpful to the intensification of pressure feeding after filling.

Study on Local Extrusions' Effects on Improvement of Die Casting Prismatic Parts' Forming Quality

2013 ◽  
Vol 312 ◽  
pp. 475-479
Author(s):  
Wei Gang Zheng ◽  
Cun Hong Yin ◽  
Yu Hong Yuan ◽  
Zhen Min Pan ◽  
Chao Tang
Keyword(s):  
Mechanical Properties ◽  
Die Casting ◽  
Casting Process ◽  
Extrusion Process ◽  
Shrinkage Porosity ◽  
Shrinkage Cavity ◽  
Prismatic Parts ◽  
Porosity Defects ◽  
Die Casting Process ◽  
Casting Production

This paper analyzes traditional die casting process to find out the reasons that cause shrinkage cavity and porosity defects in casting. An optimized process of die casting by using local extrusion is proposed. A device used in local extrusion which realizes forcing compensating contraction on key parts of crankcase is designed and the parameters of local extrusion process are discussed. Compared the mechanical properties and microstructure of local extrusion used in die casting production with traditional. It shows that local extrusion used in die casting production can not only achieve the aim eliminating shrinkage porosity and cavity of a casting but also can refine grain to improve the mechanical properties.

Numerical Simulation on the Filling Process of Rheological Die Casting and Forming Defects Analysis

2012 ◽  
Vol 192-193 ◽  
pp. 293-298 ◽  
Author(s):  
Fan Zhang ◽  
Nan Nan Song ◽  
Jun Zhang ◽  
Yong Lin Kang ◽  
Qiang Zhu
Keyword(s):  
Numerical Simulation ◽  
Die Casting ◽  
A356 Alloy ◽  
Casting Process ◽  
Solid Particles ◽  
Filling Process ◽  
Die Casting Process ◽  
Defects Analysis ◽  
Semi Solid ◽  
Forming Defects

According to semi-solid slurry rheological behavior, an apparent viscosity model of A356 alloy developed based on the Carreau model was established to simulate filling process of rheo-diecasting about automobile shock absorber parts and to compare with conventional liquid filling process. Numerical simulation results showed that the filling process of rheo-diecasting was smooth but difficult to splash, which reduced the tendency of the alloy oxidation and inclusion. Meanwhile, a certain percentage of the primary solid particles precipitated before filling and solidification shrinkage of semi-solid slurry were small. This benefited to reduce or eliminate shrinkage defects of the castings. Compared with conventional liquid die casting process, rheo-diecasting process had unique advantages in reducing the internal defects and improving mechanical properties of castings.

Multiphase modelling of the transient flow for Sn-15Pb and 357.0 alloys in semi-solid die casting process

2020 ◽  
Vol 278 ◽  
pp. 116534
Author(s):  
Wenying Qu ◽  
Daquan Li ◽  
Fan Zhang ◽  
Min Luo ◽  
Xiaogang Hu ◽  
...  
Keyword(s):  
Transient Flow ◽  
Die Casting ◽  
Casting Process ◽  
Die Casting Process ◽  
Semi Solid
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