scholarly journals INDUSTRIAL SEMISOLID CASTING PROCESS FOR SECONDARY ALUMINIUM ALLOYS FOR DECARBONISING LIGHTWEIGHT PARTS IN AUTOMOTIVE SECTOR

2020 ◽  
Vol 326 ◽  
pp. 06007
Author(s):  
Fabrizio D’Errico ◽  
Daniele Casari ◽  
Mattia Alemani ◽  
Guido Perricone ◽  
Mauro Tosto
Keyword(s):  
Aluminium Alloys ◽  
Casting Machine ◽  
Casting Process ◽  
High Energy ◽  
Fatigue Properties ◽  
Automotive Sector ◽  
Semisolid State ◽  
State Process ◽  
Process Route ◽  
Primary Aluminium

The life cycle holistic approach for the automotive sector highlighted how much important is working on decarbonisation of Al casting processes to produce vehicle components. Broadening the use of recycled aluminium alloys, instead of high energy intensive primary aluminium alloys, is key for environment preservation. While primary aluminium alloys are preferred by automotive original equipment manufacturers (OEMs) because impurities (mainly Fe) present in secondary aluminium alloys might cause fatigue properties decay, a new semisolid state process route has been developed at Brembo to drastically reduce the sensitivity of cast aluminium to Fe impurities. Based on these premises, during the CRAL European project in the framework of the LIFE Programme, an industrial prototype machinery - a vertical high pressure die casting machine - has been designed and constructed to inject secondary aluminium in the semisolid state. A number of A357 Fe-enriched brake callipers manufactured via the new process route have been fully investigated by fatigue tests, SEM and OM analyses in order to validate the new eco-sustainable product compared to conventional ones manufactured with primary aluminium by gravity casting.

Study on high-temperature wear and mechanism of Al-Si/graphite composites prepared by the die-casting process

2020 ◽  
Vol 72 (10) ◽  
pp. 1153-1158 ◽  
Author(s):  
Yafei Deng ◽  
Xiaotao Pan ◽  
Guoxun Zeng ◽  
Jie Liu ◽  
Sinong Xiao ◽  
...  
Keyword(s):  
Friction Coefficient ◽  
Wear Rate ◽  
Peer Review ◽  
Die Casting ◽  
Casting Machine ◽  
Injection Pressure ◽  
Casting Process ◽  
Matrix Alloy ◽  
Content Type ◽  
The Matrix

Purpose This paper aims to improve the tribological properties of aluminum alloys and reduce their wear rate. Design/methodology/approach Carbon is placed in the model at room temperature, pour 680°C of molten aluminum into the pressure chamber, and then pressed it into the mold containing carbon felt through a die casting machine, and waited for it to cool, which used an injection pressure of 52.8 MPa and held the same pressure for 15 s. Findings The result indicated that the mechanical properties of matrix and composite are similar, and the compressive strength of the composite is only 95% of the matrix alloy. However, the composite showed a low friction coefficient, the friction coefficient of Gr/Al composite is only 0.15, which just is two-third than that of the matrix alloy. Similarly, the wear rate of the composite is less than 4% of the matrix. In addition, the composite can avoid severe wear before 200°C, but the matrix alloy only 100°C. Originality/value This material has excellent friction properties and is able to maintain this excellent performance at high temperatures. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-10-2019-0454/

An Investigation on the Mechanical Alloying of TiFe Compound by High-Energy Ball Milling

2010 ◽  
Vol 660-661 ◽  
pp. 329-334 ◽  
Author(s):  
Railson Bolsoni Falcão ◽  
Edgar Djalma Campos Carneiro Dammann ◽  
Cláudio José da Rocha ◽  
Ricardo Mendes Leal Neto
Keyword(s):  
Ball Milling ◽  
High Energy ◽  
High Energy Ball Milling ◽  
Low Density Polyethylene ◽  
Low Density ◽  
Powder Mixtures ◽  
Milling Parameters ◽  
Process Route ◽  
Partial Formation ◽  
Energy Ball

This work reports the efforts to obtain TiFe intermetallic compound by high-energy ball milling of Ti and Fe powder mixtures. This process route has been used to provide a better hydrogen intake in this compound. Milling was carried out in a SPEX mill at different times. Strong adherence of material at the vial walls was seen to be the main problem at milling times higher than 1 hour. Attempts to solve this problem were accomplished by adding different process control agents, like ethanol, stearic acid, low density polyethylene, benzene and cyclohexane at variable quantities and keeping constant other milling parameters like ball to powder ration and balls size. Better results were attained with benzene and cyclohexane, but with partial formation of TiFe compound even after a heat treatment (annealing) of the milled samples.

scholarly journals Mechanically Alloyed Amorphous Ti50(Cu0.45Ni0.55)44–xAlxSi4B2 Alloys with Supercooled Liquid Region

2002 ◽  
Vol 17 (7) ◽  
pp. 1743-1749 ◽  
Author(s):  
L. C. Zhang ◽  
J. Xu ◽  
E. Ma
Keyword(s):  
Amorphous Alloys ◽  
Supercooled Liquid ◽  
High Energy ◽  
Supercooled Liquid Region ◽  
Liquid Region ◽  
Mechanically Alloyed ◽  
Scanning Calorimetry ◽  
Beneficial Effects ◽  
State Process ◽  
Transmission Electron

A high-energy ball milling procedure has been developed to produce amorphous alloys in Ti50(Cu0.45Ni0.55)44−xAlxSi4B2 (x= 0, 4, 8, 12) powder mixtures. The milling products were characterized using x-ray diffraction, differential scanning calorimetry, and transmission electron microscopy. The Ti-based amorphous alloy powders prepared through this solid-state process exhibit a well-defined glass transition and a supercooled liquid region (ΔTx =64 K) close to the largest achieved so far for Ti-based undercooled melts. The substitution of Al for Cu and Ni has beneficial effects on stabilizing the supercooled liquid. Residual nanocrystals of the αTi structure are uniformly dispersed in the amorphous matrix. The composite alloy powders offer the potential for consolidation in the supercooled liquid region to bulk lightweight amorphous alloys and the possibility to attain desirable mechanical properties.

A Preliminary Study of Fabrication Technology for Dynamic Compression Plates Using Centrifugal Casting Process

2021 ◽  
Vol 18 (2) ◽  
Author(s):  
A.K. Nasution ◽  
D. Gustiani ◽  
A. Handoko ◽  
Mukhtar ◽  
Zulkarnain ◽  
...  
Keyword(s):  
Low Income ◽  
Dynamic Compression ◽  
Centrifugal Casting ◽  
Casting Machine ◽  
Casting Process ◽  
Low Income Countries ◽  
Silicon Alloy ◽  
Horizontal Type ◽  
Preliminary Study ◽  
Cast Pipe

The high cost of health services in low-income countries has caused them to produce implants and medical devices at low cost. This research highlights a preliminary study of the design concept, mould design, and fabrication of horizontal type centrifugal casting machines for the manufacture of dynamic compression plates materials. Normally, dynamic compression plate is produced from materials such as 316L stainless steel, cobalt, and titanium alloys. In this work, aluminium-silicon alloy was used in this preliminary study. Aluminium-silicon alloy was melted at a temperature of 730 °C and poured into a mould with a rotational speed of 1500 rpm. Tensile, hardness and microstructure investigation were carried out to discern the mechanical properties of the cast product from the horizontal type centrifugal casting machine. Results showed the measured value of tensile strength is not significantly different in the two zones of cast pipe, the butt zone of fall of molten metal (specimen A) was 147 MPa, and the butt-end zone (specimen B) was 142 MPa. The hardness value for the as-cast pipe obtained from the outside, middle, and inside, was 104.0, 92.9, and 80.3 HV, respectively. Evaluation of microporosity in fractures (from tensile test) results from horizontal type centrifugal castings showed a small distribution. Meanwhile, the calculation of the contour hole processing time for DCP with eight holes is 38 minutes per implant.

scholarly journals Reduction of Blowholesin Aluminium High Pressure Die Casting Machine

2018 ◽  
Vol 7 (3.34) ◽  
pp. 410
Author(s):  
Nagasankar P ◽  
Sathiyamoorthy. V ◽  
Gurusamy. P ◽  
VinothKanna P ◽  
Manibharathi D ◽  
...  
Keyword(s):  
High Pressure ◽  
Manufacturing Process ◽  
Die Casting ◽  
Casting Machine ◽  
Casting Process ◽  
Magma Flow ◽  
High Pressure Die Casting ◽  
Analysis Technique ◽  
Quality Product ◽  
Pressure Die Casting

The main objective of this research is to reduce the blowholes by analyzing the factors which are affected during the casting process. The process parameters are optimized and change is made in the design part to reduce the blowhole and to increase the efficiency of the high pressure die casting machines. Product manufactured from every manufacturing process shows some defects. For supplying quality product to the customer these defects must be reduced. In this work, an attempt is made to reduce the rejection due to the blowhole defect is found out through why-why analysis technique. Process capability of current high pressure die casting manufacturing process is checked. Manufacturing process found capable to manufacture the components. Current problem of blowhole defect is solved making an improvement in design of die which we insert. In gate directions are changed so as to obtain modified improved flow pattern. Using magma flow simulationsoftware existing and modified design has then been compared. It is found that, modified design shows superior results and using this, the defect of blowholes is minimized up to satisfactory level.   

Properties and behavior of squeeze pressure on aluminum molybdenum DI-supplied composite

2018 ◽  
Vol 7 (3.3) ◽  
pp. 496
Author(s):  
S Arunkumar ◽  
M Chandrasekaran ◽  
T Vinod Kumar ◽  
V Muthuraman
Keyword(s):  
Casting Machine ◽  
Fine Powder ◽  
Hardness Test ◽  
Casting Process ◽  
Stir Casting ◽  
Furnace Temperature ◽  
Cast Material ◽  
Squeeze Pressure ◽  
And Behavior ◽  
Squeeze Casting Process

To develop a metal matrix composite with lubricative properties with the help of various casting process and they are tested for their proper-ties. Casting machine is turned ON. Furnace temperature is set to 850o C. Preheater temperature is set to 180o C. Pathway temperature is set to 550o C. The furnace is allowed to get heated up. Once it gets heated upto 600o C, the A-Si alloy is dropped into the furnace. The alloy gets melted at around 800-850o C. Molybdenum di-sulphide fine powder is preheated and then mixed with the molten metal. Molybdenum di-sulphide is a reinforcement added and it is preheated to increase the wettability. Stainless steel stirrer is used to mix the alloy and graphite well. Stirrer is rotated between 200-300rpm.Once both the alloy and reinforcement gets mixed up into a single red hot molt, it is poured. The molt now leaves from the bottom of the furnace through the pathway. Pathway is maintained at 550o C to avoid solidification of molt in the path. Pathway carries the molt to a die, where it is poured. A squeeze pressure of 30 tonnes and 60 tonnes is given on the die using a piston. Die is split up and the mould is taken out from it. The die, furnace, pathway are coated with a layer of non-stick coating to avoid the sticking of alloy in the walls. The same process is repeated in stir casting, except that, pathway is not needed. The molten alloy is poured directly into the die without any pressure being applied. The die is split and the mould is taken. Coating is done before the next casting.Graphite powder and the Al-Si alloy materials are casted using squeeze casting process. Wear strength, tensile strength, flexural strength, impact strength and hardness test for the squeeze casted material is found out. The same materials are casted with the help of the stir casting process and they are compared with the squeeze cast material. Various testing process are to be carried out on the casted material and the results are compared.  

Quality Control System for Die Castings Based on Statistic Analysis

2012 ◽  
Vol 246-247 ◽  
pp. 918-923
Author(s):  
Xiao Fang Ruan
Keyword(s):  
Quality Control ◽  
Control System ◽  
Statistical Analysis ◽  
Die Casting ◽  
Ferrous Metal ◽  
Casting Machine ◽  
Casting Process ◽  
Quality Control System ◽  
Die Castings

Die casting technology is applied widely for mass production of non-ferrous metal parts. How to guarantee the quality of die castings is always a concerned topic. A quality control system for die casting machine was developed based on statistical analysis of technology parameters. Firstly the original data is acquired from die casting machine and the technology curves are displayed. Secondly, the technology parameters are identified automatically and a database of technology parameters is established. Thirdly, a statistical analysis based on the database is performed. The statistics parameters of expecta -tion and deviation are figured out and the probability distribution diagrams for technology parameters are displayed. Finally, Tolerances for technology parameters are figured out and then the system will monitor the die casting process according to the tolerances. A practical system realization in a die casting machine is demonstrated by its monitoring interfaces. Statistical information and on-line monitoring provided by this system are helpful to guarantee the quality of die castings.

Dry and Wet Milling Comparison of Nd-Fe-B Magnets Based on Strip Cast Alloys

2017 ◽  
Vol 899 ◽  
pp. 567-571
Author(s):  
Fernando Maccari ◽  
R.V. Well ◽  
G. Eller ◽  
M.S.T. Hoffmann ◽  
Leonardo Ulian Lopes ◽  
...  
Keyword(s):  
Casting Process ◽  
High Energy ◽  
Milling Process ◽  
Grain Structure ◽  
Coarse Grained ◽  
High Coercivity ◽  
Wet Milling ◽  
Sintered Magnet ◽  
Energy Product ◽  
Cast Alloys

In this work, the influence of milling medium was investigated in order to achieve high energy-product Nd-Fe-B magnets, mostly by the remanence improvement related to the obtention of monocrystalline particles during milling. Nd-Fe-B alloy made by strip-casting process were used as starting material, which exhibits refined grain structure and demands special attention during milling in relation to coarse-grained, conventionally cast alloys. It was found that by using liquid medium during ball milling process, the mean particle size decreased, as well as the size distribution, which improved the particle alignment and hence the remanence in the sintered magnet. Texture was quantified by magnetic characterization based on reference isotropic magnets made in same conditions, and microstructure development was evaluated by optical microscopy. Moreover, after post-sintering treatment, the coercivity increased 20% compared to as sintered state without changing the remanence, providing an anisotropic magnet with high coercivity.

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