A Tool for Predicting the Effect of the Plunger Motion Profile on the Static Properties of Aluminium High Pressure Die Cast Components

Abstract

The availability of tools for predicting quality in high pressure die casting is a challenging issue since a large amount of defects is detected in components with a consequent worsening of the mechanical behavior. In this paper, a tool for predicting the effect of the plunger motion on the properties of high pressure die cast aluminum alloys is explained and applied, by demonstrating its effectiveness. A comparison between two experiments executed through different cold chamber machines and the same geometry of the die and slightly different chemical compositions of the alloy is described. The effectiveness of the model is proved by showing the agreement between the prediction bounds and the measured data. The prediction model proposed is a general methodology independent of the machine and accounts for the effects of geometry and alloy through its coefficients.

Processing–Structure–Property Relationships in Metals

“…The book gathers manuscripts from academic and industrial researchers with stimulating new ideas and original results. It consists of one review paper regarding state of art and perspectives of alloys for aeronautic applications [1] and fifteen research papers [2][3][4][5][6][7][8][9][10][11][12][13][14][15][16] focused on different materials and processes.…”

“…Another topic of utmost importance is the prediction of process-structure-property relationships for a given material that can be achieved either through suitable models or experiments. The work by Fiorese et al [8] describes a tool used for predicting the effect of the plunger motion on the properties of high-pressure die cast aluminium alloys. In fact, the proposed model is a general methodology independent of the machine and accounts for the effects of geometry and alloy through its coefficients.…”

Minimizing the Casting Defects in High Pressure Die Casting Using Taguchi Analysis

“…Plunger velocity and its motion plays an important role in the final quality of the die castings. The 1 st stage plunger velocity is linked with the filling of die casting chamber in machine, whereas the 2 nd stage plunger velocity is correlated with filling of the die cavity [19]. Air entrapment defects occur normally during the heat treatment process due to variations in the cooling temperature while dealing with the A380 alloy [20].…”

Analysis of Mechanical and Thermal Stresses in a Pressure Casting Machine Plunger

“…• In reference to the plungers used in a cold chamber pressure machine, the literature concentrates on: • Plunger movement profile [9], a) b) Fig.1. Schematics of a cold chamber pressure machine with a horizontal casting chamber [27]: (a) and a drawing of a pressure cast with the pouring system elements [14] (b) Fig.…”