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1
Content available Design and Optimization of Casting System for Integrated Longitudinal Beam and Tower Package Based on Al-Si Alloy
Heng Li, Nan Wang, Xingyu Teng, Zhen Chai, Xiaoyong Zhu, Yucheng Wu
Advances in Science and Technology. Research Journal
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2024
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Vol. 18, no 3
111--122
EN
This study optimized the integrated die-casting of an aluminum alloy longitudinal beam and tower component using no heat-treated aluminum alloy. Leveraging material properties and part geometry, a pouring system was designed and refined through mold flow analysis. This optimized the velocity, temperature distribution, and air entrapment to reduce defects like shrinkage porosity. The optimized pouring parameters were 695 °C melt temperature, 210 °C initial mold temperature, and 4.9 m/s shot speed. This reduced shrinkage porosity by 10.4% versus the original design. Die-casting trials with the optimized pouring system produced defect-free castings. The critical load-bearing section of the die casting had a yield strength of 184 MPa and elongation of 10.9%, which can meet the production requirements. In summary, based on the optimization of pouring system by mold flow analysis, by developing the integrated die casting process for aluminum alloy. Not only the defects are eliminated, but also the castings with sufficient mechanical properties are produced.
2
Stan aktualny i tendencje rozwojowe odlewnictwa ciśnieniowego na przykładzie odlewania pod ciśnieniem w USA (na kanwie rozważań Daniela L. Twaroga)
Sobczak J. J., Dudek P.
Przegląd Odlewnictwa
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2017
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Vol. 67, nr 5-6
158--166
PL
W artykule przedstawiono obecną sytuację gospodarki Stanów Zjednoczonych i perspektywy rozwoju po zmianie administracji rządowej. Wskazano na zagrożenia wynikające z konkurencji Meksyku, który staje się największym eksporterem produktów do USA. Wpływa to bezpośrednio na zmniejszenie PKB i wzrost bezrobocia w Stanach Zjednoczonych. Interwencja rządu - poprzez obniżenie podatków i wprowadzenie VAT - powinna wpłynąć pozytywnie na polepszenie wskaźników ekonomicznych. Motorem napędowym gospodarki Stanów Zjednoczonych - podobnie jak i Polski - są małe i średnie przedsiębiorstwa, których jest w USA 28 min. Przewiduje się, że zmiana przepisów odnośnie emisji szkodliwych substancji przez samochody powinna w sposób znaczący spowodować wzrost produkcji odlewów ciśnieniowych ze stopów aluminium jako tworzywa lekkiego i nadającego się w sposób ekonomiczny do powtórnego wykorzystania. Przemysł odlewniczy w 2016 roku odnotował znaczy wzrost produkcji dzięki rekordowo dużej produkcji samochodów, w tym również ciężarówek. Szacuje się, że w przemyśle odlewniczym brakuje ponad 4 min pracowników. Wynika to ze wzrostu produkcji oraz niskich zarobków w tej branży. Dlatego stawia się bardzo duży nacisk na automatyzację całego procesu. Wyzwaniem najbliższych lat będzie produkcja odlewów do samochodów elektrycznych, gdyż - według prognoz - ostatni samochód zasilany benzyną zostanie sprzedany w 2035 roku.
EN
The present situation of the United States economy and perspectives of its development after changing the government, is presented in the hereby paper. Hazards related to the Mexico competition, which becomes the largest exporter of products to the USA, are indicated. This directly decreases GDP (Gross domestic product) and causes an unemployment increase. Government intervention by lowering taxes and introducing of VAT (Value added tax) - should positively influence improvements of economic indices. The driving force of the US economy - in a similar fashion as of Poland - are small and medium enterprises, which number in the US equals 28 millions. It is expected that the change of regulations concerning emissions of harmful substances by cars should cause - to a significant degree - an increase of pressure die casting of aluminium alloys as a light material suitable for economic reusing. The foundry industry had a significant production increase in 2016 due to extremely large increase of the vehicle production, including trucks. It is estimated that there is a lack of 4 million of employees in the foundry industry. This results from the production increase and low salaries in this sector. Therefore a significant pressure is exercised on the process automating. Production of castings for electric cars will constitute the challenge of the nearest years, since - according to prognoses - the last car supplied by petrol will be sold in the year 2035.
3
Content available Premature cracking of dies for aluminium alloy die-casting
Pawłowski P., Bała P., Tokarski T., Krawczyk J.
Archives of Metallurgy and Materials
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2013
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Vol. 58, iss. 4
1275--1279
EN
Two identical dies for aluminium alloy die-casting failed prematurely because of a number of parallel cracks on the working surface. These cracks were of a mechanical nature related to incorrect microstructural banding orientation of the die core and related to improper heat treatment. The microstructural banding orientation was determined by metallographic examination of the specimens, which were cut from the dies along the three axes of the coordinate system. Scanning electron microscopy (SEM) examination of the fracture surfaces and along the crack path (including energy dispersive spectroscopy (EDS) analysis) indicated that the root cause of the premature cracking of the dies was improper heat treatment (quenching and tempering conditions). Additionally, resistance to fracture of the investigated specimens, as measured by the Charpy V-notch test, was five times lower than that required for the desired hardness.
PL
Dwie identyczne matryce do ciśnieniowego odlewania stopów aluminium zostały przedwcześnie wycofane z eksploatacji z powodu wystąpienia na ich powierzchniach roboczych szeregu równoległych pęknięć. Kierunek propagacji pęknięć pokrywał się z kierunkiem pasmowości mikrostrukturalnej a samo tworzenie się pęknięć było skutkiem niewłaściwej obróbki cieplnej matryc. Stwierdzono nieprawidłową orientację geometryczną matrycy względem kierunku włókien struktury pierwotnej. Badania przy użyciu skaningowego mikroskopu elektronowego z wykorzystaniem techniki EDS wykazały, że przyczyną powstawania pęknięć matryc była nieprawidłową przeprowadzona obróbki cieplna matryc.
4
Content available remote The new foundry line for magnesium alloys high-pressure die-casting
Błaszczyk-Malik K. N., Walczak W., Braszczyński J.
Archives of Foundry Engineering
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2008
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Vol. 8, iss. 1
27-30
EN
The new foundry line for high-pressure die-casting of magnesium alloys constructed in the "SILUM" Foundry (Opojowice, Poland) is described. In the process cold chamber die-casting machines are used. The experimental casts and the radiators fabricated using the new cold chamber die-casting line are presented as the final results. The new production line allows to obtain good quality magnesium casts.
5
Content available remote An establish attempt of reasons of machining splinter formation in AC44200 alloy high pressure die castings
Mutwil J.
Archives of Foundry Engineering
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2008
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Vol. 8, iss. 3
159-166
EN
A problem of splinter formation during machining the AC44200 alloy high pressure die casting has been experimental investigated. In order to establish the reason of this occurrence a set of 200 high pressure die casting of the tensile strength samples have been prepared. The tensile tests were carried out using a Zwick Z050 universal testing machine. JM-SPC program has been used for statistical analysis of test results. A large variability of tensile strength results has been found. In order to find the reason of this variability the fracture surface investigations (macrographs for all of samples and SEM micrographs for chosen samples) have been carried out. It has been establish that in all cases a significant decrease of tensile strength was caused by presence of inclusions or porosity. In lot of cases the inclusions have a form of oxide film.
6
Content available remote An establish attempt of reasons of machining splinter formation in AC47000 alloy high pressure die castings
Mutwil J.
Archives of Foundry Engineering
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2008
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Vol. 8, iss. 3
167-172
EN
A problem of splinter formation during machining the AC47000 alloy high pressure die casting has been experimental investigated. In order to establish the reason of this occurrence a set of 200 high pressure die casting of the tensile strength samples have been prepared. The tensile tests were carried out using a Zwick Z050 universal testing machine. JM-SPC program has been used for statistical analysis of test results. A large variability of tensile strength results has been found. In order to find the reason of this variability the fracture surface investigations (macrographs for all of samples and SEM micrographs for chosen samples) have been carried out. It has been establish that in all cases a significant decrease of tensile strength was caused by presence of inclusions or porosity.
7
Content available remote The influence of wall thickness on the microstructure of HPDC AE44 alloy
Rzychoń T., Kiełbus A.
Archives of Materials Science and Engineering
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2007
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Vol. 28, nr 8
471-474
EN
Purpose: The main objective of this study was determination of influence of wall thickness on the microstructure of die-cast magnesium alloy containing aluminum and rare earth elements. Design/methodology/approach: The study was conducted on die-cast magnesium alloy containing 4% wt. aluminum and 4% wt. mixture of rare earth elements (mischmetal) in the die-cast condition. The mischmetal includes cerium, lanthanum, neodymium and praseodymium. The microstructure was characterized by optical microscopy (Olympus GX-70) and a scanning electron microscopy (Hitachi S3400) equipped with an X-radiation detector EDS (VOYAGER of NORAN INSTRUMENTS). The phase identification of these alloys was identified by X-ray diffraction (JDX-75). Quantitative examination was conducted using the "MET-ILO" automatic image analysis programme. Findings: The decreasing of wall thickness of die-cast AE44 leads to grain size decrease and emergence new intermetallic phases in microstructure of this alloy. With increasing thickness higher porosity was observed in alloy. Research limitations/implications: Future researches should contain investigations of the influence of diecast parameters on microstructure and porosity. Practical implications: AE44 magnesium alloy is used in automotive industry. Moreover, this alloy has a new potential application and results of investigations may be useful for preparing optimal technology of die casting and designing parts of car engine. Originality/value: The results of the researches make up a basis for the next investigations of magnesium alloys with addition of aluminum and rare earth elements designed to exploitation at temperature to 200 °C.
8
Content available remote Reengineering of permanent mould casting with lean manufacturing methods
Władysiak R.
Archives of Foundry Engineering
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2007
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Vol. 7, iss. 3
205-212
EN
At the work were introduced main areas of production system project of casts produced in permanent moulds, that constitutes reengineering of conventional production system according to Lean Manufacturing (LM) methods. New resolution of cooling of dies with water mist was shown to casting of car wheels made from aluminium alloys in low pressure casting process. It was implemented as a part of goal-oriented project in R.H. Alurad Sp.z o.o. in Gorzyce. Its using intensifies solidification and self-cooling of casts shortening the time of casting cycle by the 30%. It was described reorganizing casting stations into multi-machines cells production and the process of their fast tool's exchange with applying the SMED method. A project of the system was described controlling the production of the foundry with the computer aided light Kanban system. A visualization of the process was shown the production of casts with use the value stream mapping method. They proved that applying casting new method in the technology and LM methods allowed to eliminate down-times, to reduce the level of stocks, to increase the productivity and the flow of the castings production.
9
Content available remote Odlewanie w kokilach jako energooszczędna metoda wytwarzania grubościennych odlewów
Maj M., Piekło J., Stachurski W., Pysz S.
Archiwum Odlewnictwa
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2004
|
R. 4, nr 13
159--164
PL
Ograniczenie zużycia mas formierskich przez zastąpienie ich fragmentami metalowymi lub kokilami niesie za sobą szereg korzyści związanych z ochroną środowiska. Wynika to między innymi ze zmniejszenia ilości wydzielania trujących substancji w trakcie regeneracji mas formierskich, ze zmniejszenia zużycia energii koniecznej do wykonania tony odlewu i ze zwiększenia wydajności odlewni. Tego typu kombinowane formy piaskowo kokilowe, ułatwiają realizowanie kierunkowego krzepnięcia i uzyskanie odlewu bez wad. W niniejszym artykule wykorzystując metody symulacji komputerowej, przeanalizowano korzyści wynikające z zamiany formy piaskowej na kokilę dla grubościennego żeliwnego odlewu.
EN
The limitation of the mould mass consumption by metal fragment or permanent moulds substituting results in many advantages connected with the environment protection. It follows, between other, from: the decrease of the toxic substances emission during regeneration, decrease of the energy consumption necessary to produce 1 ton of cast and from increase of foundry capacity. The combined die-sand-moulds, of this type, facilitate the realizing directional solidification and obtaining the sound casting (without defects). In this research work, by means of the computer simulation method, the advantages resulting from the change the sand-mould to the mould for thick-walled iron casting have been analyzed.
10
Content available remote Crystallization of Al-Si alloys in the course of high pressure die-casting
Nova I., Exner J., Hošek Z., Novakova I.
Archiwum Odlewnictwa
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2004
|
R. 4, nr 14
325-332
EN
The article deals with the study of crystallization processes of die-casting applied especially for the AISi9Cu3 alloy. The crystallization of the studied casting was performed by using of the microscope VEGA TS 5130. The structure was observed for thin (3mm) and in thick (11 mm) casting. There is a crystalline fine-grained structure of the die-casting. There is not a dendritic structure in the die-casting.
PL
Artykuł dotyczy badań procesów krystalizacji odlewów ciśnieniowych w szczególności stopu AISi9Cu3. Badania procesu krystalizacji testowanego odlewu zrealizowano na mikroskopie VEGA TS 5130. Analizowano strukturę odlewu w ściankach o grubości 3 mm, 11 mm. Zaobserwowano w odlewie ciśnieniowym drobnoziarnistą strukturę krystaliczną. Struktura dendrytyczna nie występowała w badanym odlewie.
11
Content available remote Comparison of the experimental and the simulation method of establishing residual stress in Al-alloys
Čech J., Palán K., Zalaba R., Švaříček K., Bařinová D.
Archiwum Odlewnictwa
|
2004
|
R. 4, nr 14
93-103
EN
The radiographic and the strain-gauge (drill hole) methods were used in evaluating the residual stress fields in Al-alloys. Two simulation software programs (MAGMA, SIMTEC) were used to compare the residual stress values established. Discussed in the paper are the potentials of individual methods, possible errors and the determination of residual stress at the critical points in the wall thickness of the casting.
PL
Do oceny pola naprężeń w stopach aluminium użyto metody rentgenograficznej i metody naprężenia kontrolnego. Dwa programy symulacyjne (MAGMA i SIMTEC) zostały użyte do porównania wyznaczonych wartości naprężeń. W artykule omówiono potencjał użytych metod, możliwe do popełnienia błędy i wyznaczenie wartości naprężeń szczątkowych w krytycznych miejscach na grubości ścianki odlewu.
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