Examples of Damage: Fractures and Crack Formation in Zinc Die Casting Components

2014 ◽  
Vol 51 (12) ◽  
pp. 860-874
Author(s):  
H. Hoche
Keyword(s):  
Crack Formation ◽  
Die Casting

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

2021 ◽  
Vol 6 (1 (114)) ◽  
pp. 81-86
Author(s):  
Hassan Abdurssoul Abdulhadi
Keyword(s):  
Temperature Distribution ◽  
Numerical Analysis ◽  
Magnesium Alloy ◽  
Structural Analysis ◽  
Magnesium Alloys ◽  
Crack Formation ◽  
Die Casting ◽  
Formation Zone ◽  
Strain Relationship ◽  
Aluminum And Magnesium Alloys

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.

Determination of the metal toughness components in impact-bending test

2018 ◽  
Vol 84 (12) ◽  
pp. 68-72
Author(s):  
A. B. Maksimov ◽  
I. P. Shevchenko ◽  
I. S. Erokhina
Keyword(s):  
Crack Growth ◽  
Specific Energy ◽  
Crack Formation ◽  
Crack Nucleation ◽  
Scale Effects ◽  
Linear Equations ◽  
Bending Test ◽  
Cross Sectional ◽  
Two Samples ◽  
Sample Width

A method for separating the work of impact into two parts - the work of the crack nucleation and that of crack growth - which consists in testing two samples with the same stress concentrators and different cross-sectional dimensions at the notch site is developed. It is assumed that the work of crack nucleation is proportional to the width of the sample face on which the crack originates and the specific energy of crack formation, whereas the work of the crack growth is proportional to the length of crack development and the specific crack growth energy. In case of the sample fracture upon testing, the crack growth length is assumed equal to the sample width. Data on the work of fracture of two samples and their geometrical dimensions at the site of the notch are used to form a system of two linear equations in two unknowns, i.e., the specific energy of crack formation and specific energy of crack growth. The determined specific energy values are then used to calculate the work of crack nucleation and work of crack growth. The use of the analytical method improves the accuracy compared to graphical - extrapolative procedures. The novelty of the method consists in using one and the same form of the notch in test samples, thus providing the same conditions of the stress-strain state for crack nucleation and growth. Moreover, specimens with different cross-section dimensions are used to eliminate the scale effects. Since the specific energy of the crack nu-cleation and specific energy of the crack growth are independent of the scale factor, they are determined only by the properties of the metal. Introduction the specific energy of crack formation and growth makes possible to assign a specific physical meaning to the fracture energy.

APEX 39

Alloy Digest ◽  
1959 ◽  
Vol 8 (1) ◽  
Keyword(s):  
Fracture Toughness ◽  
Corrosion Resistance ◽  
High Temperature ◽  
Physical Properties ◽  
Tensile Properties ◽  
Die Casting ◽  
Casting Alloy ◽  
Alloy Ingot ◽  
Temperature Performance

Abstract APEX 39 is an aluminum die casting alloy ingot containing copper and silicon. It has excellent castability and improved machinability. This datasheet provides information on composition, physical properties, hardness, elasticity, and tensile properties as well as fracture toughness. It also includes information on high temperature performance and corrosion resistance as well as casting and machining. Filing Code: Al-75. Producer or source: Apex Smelting Company.

MAGNESIUM AZ91B

Alloy Digest ◽  
1958 ◽  
Vol 7 (1) ◽  
Keyword(s):  
Fracture Toughness ◽  
Corrosion Resistance ◽  
Shear Strength ◽  
Physical Properties ◽  
Surface Treatment ◽  
Tensile Properties ◽  
Die Casting ◽  
Casting Alloy ◽  
Casting Industry ◽  
Magnesium Die Casting

Abstract MAGNESIUM AZ91B is a standard magnesium die casting alloy patterned for the needs of the commercial casting industry. This datasheet provides information on composition, physical properties, hardness, elasticity, tensile properties, and compressive and shear strength as well as fracture toughness and fatigue. It also includes information on corrosion resistance as well as casting, machining, and surface treatment. Filing Code: Mg-36. Producer or source: Apex Smelting Company.

COPPER ALLOY No. 878

Alloy Digest ◽  
1979 ◽  
Vol 28 (12) ◽  
Keyword(s):  
Fracture Toughness ◽  
Wear Resistance ◽  
Corrosion Resistance ◽  
Copper Alloy ◽  
Die Casting ◽  
Heat Treating ◽  
Casting Alloys ◽  
Copper Zinc ◽  
Die Castings ◽  
Very High

Abstract Copper Alloy No. 878 is a copper-zinc-silicon alloy for die castings. Among the brass die-casting alloys, it has the highest strength, hardness and wear resistance; however, it is the most difficult to machine. It is used where very high requirements must be met for strength and wear resistance. Its many applications include tools, pump impellers, gears and marine hardware. This datasheet provides information on composition, physical properties, hardness, elasticity, and tensile properties as well as fracture toughness. It also includes information on corrosion resistance as well as casting, heat treating, machining, and joining. Filing Code: Cu-386. Producer or source: Copper alloy producers.

BIRMAL P.83

Alloy Digest ◽  
1960 ◽  
Vol 9 (12) ◽  
Keyword(s):  
Corrosion Resistance ◽  
Shear Strength ◽  
High Temperature ◽  
Physical Properties ◽  
Tensile Properties ◽  
Die Casting ◽  
Heat Treating ◽  
Casting Alloy ◽  
Temperature Performance ◽  
Aluminum Castings

Abstract Birmal P.83 is an aluminum-copper-silicon die casting alloy, having excellent castability and improved machinability. This datasheet provides information on composition, physical properties, hardness, elasticity, tensile properties, and shear strength as well as fatigue. It also includes information on high temperature performance and corrosion resistance as well as casting, heat treating, and machining. Filing Code: Al-98. Producer or source: Birmingham Aluminum Castings Company Ltd.

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