Development of an Innovative Low Pressure Die Casting Process for Aluminum Powertrain and Structural Components

Merchán, Mikel; Egizabal, Pedro; Cortázar, Maider García de; Irazustabarrena, Ane; Galarraga, Haize

doi:10.1002/adem.201800105

Cited by 8 publications

(7 citation statements)

References 10 publications

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“…Their modified process is designated low pressure squeeze casting (LPSC) and incorporates the exertion of pressure on the solidifying casting to improve, through supporting direct contact between part and mold, heat extraction from the casting, thus increasing solidification rates, and reduce porosity by keeping larger amounts of gases in solution and providing internal feeding effects. Among the results are reduced cycle times as well as increased strength, fatigue life and elongation at failure …”

Section: Contributions To the Euromat Symposiummentioning

confidence: 99%

New Materials and Processes for Transport Applications: Going Hybrid and Beyond

et al. 2019

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The present text introduces a Special Section of Advanced Engineering Materials linked to the symposium Advanced Materials for Transport Applications organized by the authors within the framework of the EUROMAT 2017 conference. It introduces the contributions that make up this Special Section, and takes the fact that a majority of them is related to the broader topic of hybrid materials and structures as a motivation for a short overview of this exciting area of research.

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Section: Contributions To the Euromat Symposiummentioning

confidence: 99%

New Materials and Processes for Transport Applications: Going Hybrid and Beyond

et al. 2019

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“…The manufacture of molded automotive parts (particularly cylinder heads) comprises alloys from the 3xx.x series (Al-Si-Mg/A356, Al-Si-Cu, Al-Si-Mg-Cu/A354) [ 5 , 6 , 7 , 8 , 9 ]. These alloys are considered to possess good castability [ 10 , 11 ], relatively low weight, and moderate mechanical properties [ 5 , 6 , 7 , 8 , 9 ]. Approximately 100% of engine pistons, about 80–85% of exhaust manifolds, 70–75% of combustion engine cylinder heads and gearbox housings, and other power transmission components such as drive shafts, rear axles, and differential casings are manufactured in the form of metal casting [ 2 , 5 , 12 ].…”

Section: Introductionmentioning

confidence: 99%

Investigating the Effect of Fly Ash Addition on the Metallurgical and Mechanical Behavior of Al-Si-Mg-Cu Alloy for Engine Cylinder Head Application

et al. 2022

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The authors researched the physical, metallurgical, and mechanical characteristics of A354 alloy (Al-Si-Mg-Cu) reinforced with 5, 10, and 15 wt% of fly ash metal matrix composites. A baseline alloy and three composites were fabricated by a liquid metallurgy route and poured into a permanent mold to obtain cast rods of dimension Φ32 mm × 156 mm. The metallurgical characterization of the developed alloy and metal matrix composites was conducted using energy-dispersive spectroscopy (EDS), field-emission scanning electron microscopy (FESEM), and X-ray diffraction. All the developed composites showed a pore-free nature, but only A354 alloy reinforced with 5 wt% of fly ash (AF5) possessed a homogeneous distribution and perfect bonding of the fly ash with the A354 matrix. Therefore, transmission electron microscopy (TEM) analysis was performed on the sample AF5. All developed alloys and metal matrix composites were subjected to hardness and mechanical property tests. It was observed that the AF5 sample had 170 ± 5.6 HV and tensile strength of 216 ± 2.3 MPa, 18.8% and 24.8% higher than the A354 matrix, but the ductility (6.5 ± 0.43%) was reduced by 23% from the baseline alloy. Finally, the fractography analysis was conducted on all the samples using FESEM to analyze the fracture mode. The fabricated 5 wt% fly ash-based metal matrix composite showed better mechanical performance than other samples. Hence, sample AF5 is suggested for manufacturing components in automotive and structural parts.

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“…Proper fabrication of aluminium castings is significant due to the vast possibilities of casting to produce various structural parts. The use of casting technologies allows for the manufacture of details with a complex structure that are components of vehicles, machinery, equipment, or measuring instruments [ 18 , 19 , 20 , 21 , 22 , 23 ]. Considering the progressive development in the complexity of structures and the associated increase in requirements for the components used, it is necessary to conduct material and technical research.…”

Section: Introductionmentioning

confidence: 99%

Model of Diagnosing and Searching for Incompatibilities in Aluminium Castings

Pacana

Czerwińska

2021

Materials

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An essential element of any industry is castings, which is determined by the technical conditions for their reception. However, conducting production in the foundry technology is burdened with many difficulties associated with, for example, the inability to control all of the parameters that may affect the casting quality. Therefore, it is essential to undertake improvement actions in this area. Efforts are being made to use non-destructive testing (NDT) as a part of quality control, but these methods are rarely combined in a single diagnostic run. As a part of quality improvement, it is also essential to identify the root cause of the problem. For this reason, it is justified to develop a model of diagnosing and searching for non-conformities, which would combine NDT tests and quality management tools. The model included the visual, ultrasound, and eddy current examination in the diagnostic part, and the Pareto–Lorenz diagram correlated with ABC method, histogram, and 5WHY method (asking five questions why). The study’s originality is manifested in the combination of several NDT methods with quality management methods in one model. Using integrally configured methods in the proposed model, it was possible to: reduce diagnostic uncertainty, characterize the critical group of non-conformities, and identify the root causes of the quality problem. The model is a new and universal method that can be implied in any foundry company in order to ensure the stability of the production processes. The application of the model contributes to an increase in the detection speed and enables the reduction of non-conformities in aluminium castings, thus increasing the quality level of the offered products.

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Development of an Innovative Low Pressure Die Casting Process for Aluminum Powertrain and Structural Components

Cited by 8 publications

References 10 publications

New Materials and Processes for Transport Applications: Going Hybrid and Beyond

New Materials and Processes for Transport Applications: Going Hybrid and Beyond

Investigating the Effect of Fly Ash Addition on the Metallurgical and Mechanical Behavior of Al-Si-Mg-Cu Alloy for Engine Cylinder Head Application

Model of Diagnosing and Searching for Incompatibilities in Aluminium Castings

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