A New DC Casting Technology for Extrusion Billets with Improved Surface Quality

Hákonsen, Arild; Hafsás, John Erik; Ledal, Rune

doi:10.1007/978-3-319-48144-9_146

Cited by 3 publications

(2 citation statements)

References 3 publications

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“…The outer surface of hard alloy billets is commonly machined and removed before the extrusion process by turning or peeling. This is because the casting method employed for these alloys causes substantial surface segregation in these billets (normally hot-top mold with no gas) [20].…”

Section: Fig 7 Typical Surface Roughness Of Aluminum Billetmentioning

confidence: 99%

The Start-Up Phase of Aluminum Billet Production Using Direct Chill Casting

Rajagukguk,

Suyitno,

Saptoadi

et al. 2024

AMM

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Direct chill (DC) casting has been considered as one of the promising casting methods that can be used to produce aluminum alloys billet. The process is conducted by pouring aluminum metal into a water-cooled mold. The billet shell begins to form when molten aluminum contact directly with the mold (this is also known as primary cooling). Afterward, the starting block is pulled downwards at a specified casting speed to achieve desired aluminum billet. The start-up phase during the DC casting process is considered a crucial step since it may determine the formation of defects in the casting products. This research aims to investigate the casting defects on the aluminum alloy that were formed during the start-up process of DC casting. The results show that the billet failed to form following the downward movement of starting block. Meanwhile, the billet tended to stick to the mold wall due to several factors, such as too low a pouring temperature, a less-round mold shape, the poor quality of the hot top and graphite ring, and the water that entered the mold during the casting process. It also noted several markers of the casting defects that occurred during the DC casting process such as liquation or bleeding, cold folding, billet stuck in the mold, butt structure, and rough billet surface.

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Section: Fig 7 Typical Surface Roughness Of Aluminum Billetmentioning

confidence: 99%

The Start-Up Phase of Aluminum Billet Production Using Direct Chill Casting

Rajagukguk,

Suyitno,

Saptoadi

et al. 2024

AMM

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“…Nunes et al [23] provide a comparative analysis of low-and highpressure casting technologies, highlighting the reduced tendency of defect formation in lowpressure casting technologies. While LPC material has primarily found application within extrusion, reportedly increasing yield and productivity [24], its potential in aluminum forging remains unexplored despite the improved quality and available dimensions.…”

Section: Introductionmentioning

confidence: 99%

The Potential of Cast Stock for the Forging of Aluminum Components within the Automotive Industry

Arbo,

Tjøtta,

Boge

et al. 2024

Metals

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In the automotive industry, there is a drive to reduce environmental impact, energy consumption, and costs related to the manufacturing of forged aluminum suspension components. The replacement of extruded stock with cast forging stock is one option that offers substantial potential for such savings. The casting technology, low-pressure casting (LPC), allows for production of high-quality cast forging stock with minimal surface segregation and smaller diameters than those achieved with traditional casting technologies. This study is a proof-of-principle, conducted to directly compare the microstructure and mechanical properties of LPC and extruded material after forging, through both generic and full-scale industrial forging trials. The results show the advantages of the cast material, including higher robustness against surface grain growth after forging and a positive correlation between mechanical properties, both strength and ductility and the introduction of plastic deformation. Overall, the work demonstrates how forged aluminum components produced from LPC forging stock can achieve mechanical properties and performance, on par with extruded forging stock, showcasing industrial relevance through the production of a safety-critical automotive component.

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Extrusion

2015

SOSEI-TO-KAKOU

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A New DC Casting Technology for Extrusion Billets with Improved Surface Quality

Cited by 3 publications

References 3 publications

The Start-Up Phase of Aluminum Billet Production Using Direct Chill Casting

The Start-Up Phase of Aluminum Billet Production Using Direct Chill Casting

The Potential of Cast Stock for the Forging of Aluminum Components within the Automotive Industry

Extrusion

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