A review of magnesium die-castings for closure applications

Weiler, J.P.

doi:10.1016/j.jma.2019.02.005

Cited by 96 publications

(20 citation statements)

References 5 publications

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“…Molten magnesium spontaneously ignites when exposed to the atmosphere. Hence, magnesium die casting [3] companies know that the magnesium melt has to be blanketed by heavy gases such as SO 2 or SF 6 . Iron/steel dust must not be mixed with aluminum dust in metal processing workshops in order to avoid a dangerous "termite" reaction.…”

Section: Metals and Metal Firesmentioning

confidence: 99%

Controlling Metal Fires through Cellulose Flake Blanketing Followed by Water Spray Cooling

Hagauer¹,

MATLSCHWEIGER²,

Tippelreither³

et al. 2022

Fire

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The traditional methods of fighting metal fires are not always safe for firefighters. The sand and salts that are thrown onto the fire to suffocate the flames can lead to splashes of molten metal, putting the firefighters and the surroundings at risk. A novel process is described where magnesium fires are brought under control using a simple two-step process. First, coated cellulose flakes, which contain approx. 30% inorganic salts, are blown onto the fire from a distance of several meters. Due to its low bulk density, the material settles smoothly on the fire and immediately covers the flames for several seconds. Before the hot metal can break through this cover, a fine water spray is applied to the fire. The water spray wets the top layer of the cellulose flakes, which will begin to char from the bottom. The water evaporates from within the cellulose flake layer and withdraws heat. It was observed that no hydrogen is formed and that this technique can safely control fires. It is judged that 90 kg of flakes could safely bring a pile of 75 kg of burning Mg flakes under control. By using a pneumatic conveying unit for the flakes, firefighters can effectively and efficiently cover the flames from a safe distance. This novel method could be recommended to firefighters in industrial magnesium processing plants, as well as local firefighters in the vicinity of such plants.

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Section: Metals and Metal Firesmentioning

confidence: 99%

Controlling Metal Fires through Cellulose Flake Blanketing Followed by Water Spray Cooling

Hagauer¹,

MATLSCHWEIGER²,

Tippelreither³

et al. 2022

Fire

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“…The results indicate that fatigue resistance of maraging steel weld is lower than the AISI H11 tools [1]. The mass of automotive can be decreased by using magnesium-based die casting because magnesium die casting has the advantage of near net shape forming, light weight, optimized strength to weight ratio, consolidation of part and additional components integration [2].…”

Section: Introductionmentioning

confidence: 96%

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

Abdulhadi

2021

EEJET

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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.

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“…So, a high thermal gradient casting was studied and optimized by designing a better cooling system. Weiler 13 stated that magnesium die casting can be used in various applications as they have superior mechanical properties and can be easily manufactured through the HDPE. Hu 14 et al observed that numerical simulation is a cost-effective tool for optimizing and designing the gating system which was used for the hot chamber die casting of a thin-walled magnesium telecommunication part.…”

Section: Introductionmentioning

confidence: 99%

Exploring Casting Defects of AA7075 Alloy in the Gravity Die Casting Simulation of an IC Engine Block

Aneesh

Pawan

Mohan

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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The present work aims to investigate the different casting defects that arose during the gravity die casting process of an IC engine block made of AA 7075 alloy and also highlights the feasible solutions to eradicate those defects. The minimization of the casting defects is a very crucial task in an IC engine block. Experimental studies which are generally performed to reduce the casting defects are proven to be strenuous, costly, and time-consuming. To counter this, a thermal simulation model is proposed in the present study to identify the effect of the pouring temperature, mould temperature, and the number of chillers on the various casting defects such as cold shuts, air entrapment, mould erosion, and microporosity. A detailed parametric study is conducted on the proposed model to evaluate the outcomes of important process variables on the resulting casting defects. The simulation results predict, at pouring temperature of 963 K, mould temperature of 293.15 K and with the use of 2 chillers defect-free IC engine blocks can be casted. The optimum result obtained by the proposed model is validated by conducting a confirmative test predicting an average error of 6.98%. The proposed model is effective enough in getting rid of the numerous casting defects which cannot be identified using the traditional methods; thus increasing productivity. This can be used as an economical time-saving substitute to the experimental methods during casting of various engine parts.

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A review of magnesium die-castings for closure applications

Cited by 96 publications

References 5 publications

Controlling Metal Fires through Cellulose Flake Blanketing Followed by Water Spray Cooling

Controlling Metal Fires through Cellulose Flake Blanketing Followed by Water Spray Cooling

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

Exploring Casting Defects of AA7075 Alloy in the Gravity Die Casting Simulation of an IC Engine Block

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