Evaluation of soldering, washout and thermal fatigue resistance of advanced metal materials for aluminum die-casting dies

Zhu, Yulong; Schwam, David; Wallace, John F.; Birceanu, Sebastian

doi:10.1016/j.msea.2004.03.020

Cited by 73 publications

(33 citation statements)

References 13 publications

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“…1 Hundred thousands of castings is the typical life cycle of a die in high-pressure die casting (HPDC), although some dies fail even after just 5-25 thousand cycles.…”

Section: Introductionmentioning

confidence: 99%

Improving die casting processes through optimization of lubrication

Fiorese

Bonollo

Battaglia

et al. 2016

International Journal of Cast Metals Research

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Lubrication plays a significant role among the processes that affect aesthetic quality in die casting. Nevertheless, comprehensive investigations are still missing in literature. In this paper, the effect of lubrication is investigated and optimized, by focusing on its influence on the die temperature. Indeed, since the surface quality of castings is related to the interaction between melt and die, lubrication allows ejection of castings without generating defects and cooling of the die, by preserving its surface. Hence, the die temperature should be accurately selected and spraying should be improved to achieve the optimal temperature. In the experimentation proposed, the lubricant release agent percentage and the lubrication duration have been varied to trade-off between some conflicting effects, while making the die temperature approach the 'Nukiyama point'. At the same time, reduction of the cycle time has been obtained. The results corroborate the approach, since defects are reduced after optimization.

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“…1 Hundred thousands of castings is the typical life cycle of a die in high-pressure die casting (HPDC), although some dies fail even after just 5-25 thousand cycles.…”

Section: Introductionmentioning

confidence: 99%

Improving die casting processes through optimization of lubrication

Fiorese

Bonollo

Battaglia

et al. 2016

International Journal of Cast Metals Research

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“…Molds or crucibles made of metallic materials are sometimes used to handle liquid melts, especially those with low melting points, in hot dipping and casting processes [1][2][3]. For aluminum casting or die-casting, iron-based alloys are the most commonly used molding materials.…”

Section: Introductionmentioning

confidence: 99%

Solid/liquid interaction between a multicomponent FeCrNiCoMnAl high entropy alloy and molten aluminum

Yang

Tsai

Kuo

et al. 2011

Journal of Alloys and Compounds

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“…The objective of developing corrective actions for a wide range of situations has led several researchers to thoroughly investigate the formation and the control of defects. Most of the focus has been on the structural defects and the surface defects from die wear, which are beyond the scope of this report; citing only a few references from a broad range of literatures, they include gas and shrinkage porosity [9], degradation of mechanical properties [10,11], and soldering, heat checking and erosion [12,13].…”

Section: Background and Literaturementioning

confidence: 99%

Cold flow defects in zinc die casting: prevention criteria using simulation and experimental investigations

Armillotta

Fasoli²,

Guarinoni

2015

Int J Adv Manuf Technol

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High-pressure die casting of zinc alloys is increasingly used in the manufacturing of parts with high aesthetic value. These parts must comply with strict requirements on surface quality, which are generally overlooked in traditional mechanical applications. Cold flow defects, which are a primary concern for surface quality, originate from several different causes that have not yet been fully understood. This report investigates the factors that influence cold flow defects and the choices that can lead to an improvement in surface quality. The research method is based on a case study performed at a die casting company. First, an existing process has been analyzed using simulation to explain the causes of cold flow defects observed in production samples. The temperature at the end of the cavity fill has emerged as a key index for the occurrence of defects, which can be controlled by three primary process parameters: injection velocity, temperature of the cooling medium, and lubricant spraying time. These same factors are then assessed using experimental tests on an existing die, where the number of defects in the selected regions of the casting has been evaluated by image processing. The results suggest that the surface quality can be particularly improved by increasing the flow rate of the molten metal through the gates and avoiding excessive flow turbulence in the wide cavity sections. Consequently, the increase in the gate area has been identified as a specific criterion for the die design. These findings have been validated in the redesign of the die and the selection of the process parameters, which have resulted in a significant reduction in the surface defects.

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Evaluation of soldering, washout and thermal fatigue resistance of advanced metal materials for aluminum die-casting dies

Cited by 73 publications

References 13 publications

Improving die casting processes through optimization of lubrication

Improving die casting processes through optimization of lubrication

Solid/liquid interaction between a multicomponent FeCrNiCoMnAl high entropy alloy and molten aluminum

Cold flow defects in zinc die casting: prevention criteria using simulation and experimental investigations

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