scholarly journals Research and Evaluation of the Influence of the Construction of the Gate and the Influence of the Piston Velocity on the Distribution of Gases into the Volume of the Casting

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2264
Author(s):  
Ján Majerník ◽  
Štefan Gašpár ◽  
Jozef Husár ◽  
Ján Paško ◽  
Jan Kolínský
Keyword(s):  
Die Casting ◽  
Main Idea ◽  
Casting Process ◽  
Gating System ◽  
Technological Parameters ◽  
Piston Velocity ◽  
Casting Cycle ◽  
Suitable Structure ◽  
Filling Phase ◽  
Die Casting Process

Distribution of gasses to the cast volume and volume of pores can be maintained within the acceptable limits by means of correct setting of technological parameters of casting and by selection of suitable structure and gating system arrangement. The main idea of this paper solves the issue of suitability of die casting adjustment—i.e., change of technological parameters or change of structural solution of the gating system—with regards to inner soundness of casts produced in die casting process. Parameters which were compared included height of a gate and velocity of a piston. The melt velocity in the gate was used as a correlating factor between the gate height and piston velocity. The evaluated parameter was gas entrapment in the cast at the end of the filling phase of die casting cycle and at the same time percentage of porosity in the samples taken from the main runner. On the basis of the performed experiments it was proved that the change of technological parameters, particularly of pressing velocity of the piston, directly influences distribution of gasses to the cast volume.

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.

Semisolid Die-Casting Process of Mg-20Al-0.8Zn Magnesium Alloy

2011 ◽  
Vol 306-307 ◽  
pp. 539-543
Author(s):  
Feng Yun Yan ◽  
Xiao Feng Huang ◽  
Bo Li ◽  
Ying Ma
Keyword(s):  
Tensile Strength ◽  
Die Casting ◽  
Injection Pressure ◽  
Casting Process ◽  
Elongation Rate ◽  
Isothermal Heat Treatment ◽  
Technological Parameters ◽  
Injection Speed ◽  
Die Casting Process ◽  
Spherical Grains

Based on microstructure evolution of Mg-20Al-0.8Zn magnesium alloys realized by semisolid isothermal heat-treatment (SSIT), we obtained the non-dendrite or spherical grains microstructure under the suitable technological parameters that isothermal temperature is 495 °C and holding time is 120 min. With the help of special experimental equipment, the semisolid die-casting process has been studied and the specimens have been analyzed. The effects of different parameters as injection speed and pressure on tensile strength, elongation rate, hardness, etc have been investigated. The results indicate that tensile strength was improved along with increasing injection speed and pressure. However, excessive speed will involve gas, which formed defects and reduced the mechanical properties. When the injection pressure is 40MPa and injection speed is 4m/s, the tensile strength and elongation rate can reach maximal 220MPa and 5.63% respectively. Its fracture mechanism was intercrystalline cracking.

scholarly journals The Influence of Pressure Die Casting Parameters on the Castability of AlSi11-SiCp Composites

2015 ◽  
Vol 15 (1) ◽  
pp. 29-34 ◽  
Author(s):  
Z. Konopka ◽  
A. Zyska ◽  
M. Łągiewka ◽  
M. Nadolski
Keyword(s):  
Die Casting ◽  
Casting Process ◽  
Regression Equations ◽  
Alloy Matrix ◽  
Piston Velocity ◽  
Second Stage ◽  
Measurement Results ◽  
Intensification Pressure ◽  
Die Casting Process ◽  
Pressure Die Casting

Abstract The paper presents the method of preparing a composite slurry composed of AlSi11 alloy matrix and 10 vol.% of SiC particles, as well as the method of its high-pressure die casting and the measurement results concerning the castability of the obtained composite. Composite castings were produced at various values of the piston velocity in the second stage of injection, diverse intensification pressure values, and various injection gate width values. There were found the regression equations describing the change of castability of the examined composite as a function of pressure die casting process parameters. The conclusion gives the analysis and the interpretation of the obtained results.

scholarly journals Effect of Multipoint Sequential Water Mist Cooling of Casting Die on Microstructure and Mechanical Properties of AlSi11 Alloy

2012 ◽  
Vol 12 (4) ◽  
pp. 145-150
Author(s):  
R. Władysiak
Keyword(s):  
Mechanical Properties ◽  
Cooling System ◽  
Die Casting ◽  
Computer Control ◽  
Casting Process ◽  
Water Mist ◽  
Microstructure And Mechanical Properties ◽  
Casting Cycle ◽  
Mist Cooling ◽  
Die Casting Process

Abstract The work is a continuation of research on the use of water mist cooling in order to increase efficiency of the die-casting process for aluminum alloys. The paper describes the multipoint sequential cooling system of the casting die and its computer control and monitoring. It also includes results of the tests and analysis of cooling methods during making of the casting. These methods differ from each other in the sequence of casting die cooling and cause effective changes in microstructure and mechanical properties of castings made of AlSi11 alloy. The study demonstrated that the use of multipoint sequential cooling with water mist affects the microstructure refinement and reduces the segregation in the cast as well as more than by 20% increases the mechanical properties of castings in the rough state. The study also demonstrates that the sequential cooling of casting die accelerates the cooling of the casting and shortens die-casting cycle.

Die Casting Improvements through Melt Shear

2009 ◽  
Vol 618-619 ◽  
pp. 33-37 ◽  
Author(s):  
Robert G. O'Donnell ◽  
Dayalan R. Gunasegaram ◽  
Michel Givord
Keyword(s):  
Die Casting ◽  
Casting Process ◽  
Shrinkage Porosity ◽  
Thermal Gradients ◽  
Casting Defects ◽  
Melt Flow ◽  
Complex Process ◽  
Casting Cycle ◽  
Die Casting Process ◽  
Contraction Stage

Melt flow and solidification within a die casting cavity is a complex process dependent in part on melt pressure (with or without intensification), melt velocity, melt flow path, thermal gradients within the die, die lubrication and melt viscosity. Casting defects such as short shots, cold shuts and shrinkage porosity can readily occur if casting conditions are not optimised. Shrinkage porosity in particular is difficult to eradicate from castings that comprise thick sections, since these sections will usually solidify late in the casting cycle and may be starved of melt supply during the critical solidification (and contraction) stage. The current work seeks to elucidate the influence of the melt shearing on the die casting process and demonstrates that the modifications made to the melt through introduction of a local constriction in the melt path can generate improvements in casting microstructure and reduce shrinkage porosity.

The Influence of the Tablet Height and Plunger Pressing Velocity on the Final Porosity of Die Casting

2018 ◽  
Vol 916 ◽  
pp. 244-248
Author(s):  
Stefan Gaspar ◽  
Jan Pasko ◽  
Dusan Knezo
Keyword(s):  
Die Casting ◽  
Casting Process ◽  
Factors Affecting ◽  
Correct Determination ◽  
Casting Cycle ◽  
Gate System ◽  
Final Porosity ◽  
Die Casting Process ◽  
Pressure Die Casting

With a pressure die casting process, one of the important factors affecting the quality of castings represented by porosity is plunger pressing velocity determines the regime die cavity filling and correct determination of dose mass of a molten metal required for one casting cycle. The mass is given by a total of the net mass of a casting, overflows, a gate system and a metal rest inside a filling chamber (the tablet height). As a rule, the tablet height represents the largest mass ratio regarding the waste metal. A correct determination of the tablet height is important from both economical and qualitative aspect of a pressure die casting process.

scholarly journals The Influence of Pressure Die Casting Parameters on the Mechanical Properties of AlSi11/10 Vol.% SiC Composite

2014 ◽  
Vol 14 (1) ◽  
pp. 59-62
Author(s):  
Z. Konopka ◽  
A. Pasieka
Keyword(s):  
Mechanical Properties ◽  
Die Casting ◽  
Casting Process ◽  
Regression Equations ◽  
Alloy Matrix ◽  
Piston Velocity ◽  
Measurement Results ◽  
Intensification Pressure ◽  
Die Casting Process ◽  
Pressure Die Casting

Abstract The paper presents the method of preparing a composite slurry composed of AlSi11 alloy matrix and 10 vol.% of SiC particles, as well as the method of its high-pressure die casting and the measurement results concerning the tensile strength, the yield point, the elongation and hardness of the obtained composite. Composite castings were produced at various values of the piston velocity in the second stage of injection, diverse intensification pressure values, and various injection gate width values. There were found the regression equations describing the change of mechanical properties of the examined composite as a function of pressure die casting process parameters. The conclusion gives the analysis and the interpretation of the obtained results.

scholarly journals Assessment of the suitability of a gate design modification compared to the change in pressing velocity considering the distribution of gases in the casting volume

2021 ◽  
Vol 1199 (1) ◽  
pp. 012003
Author(s):  
J Majernik ◽  
M Tupaj ◽  
A Trytek ◽  
M Podařil
Keyword(s):  
Gas Content ◽  
Design Solution ◽  
Gating System ◽  
Melt Flow ◽  
Technological Parameters ◽  
Piston Velocity ◽  
Design Modification ◽  
Casting Cycle ◽  
Gas Entrapment ◽  
Gate Design

Abstract The qualitative properties of high pressure die castings are closely correlated with their internal structure, which is directly conditioned by the gas entrapment in the melt volume during the casting cycle. It is known that the gas entrapment in the volume of the melt and their subsequent distribution into the cast can be reduced by changing the technological parameters of the casting cycle or by the modification of the gating system design. The contribution addresses the issue of which variant of the gas content reduction is more efficient regarding the gas entrapment and the nature of the melt flow in the runners. The experiments are based on a real casting process. The established design solution of the gating system and the technological parameters setting are considered as a referential. Different gating system modifications were designed where the design modification is connected with the cross-section of a gate, in which the final acceleration of the melt flow occurs. The observed melt velocity in the gate is considered as a correlation factor, based on which the modification in the piston velocity is determined. The assessed parameter is the gas entrapment in the cast volume at the end of the filling phase. Assessment of the casting cycle and evaluation of experiments is performed using simulation program Magmasoft. Based on the performed analyses, it can be stated that the gate design modification will affect the filling regime of the die cavity by changing the melt velocity in gate, but the nature of the melt flow in runners remains unchanged. Modification of the piston velocity affects the filling regime of the die cavity, and also the nature of the melt flow as it passes through the runners, thereby promoting the gas entrapment in the melt volume. Therefore, it is necessary to pay an increased attention to the design of the gating system and only after debugging the design to proceed to the optimization of technological parameters.

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