Lost Cores for High-Pressure Die Casting

Jelínek, Petr; Adámková, Eliška

doi:10.2478/afe-2014-0045

Cited by 22 publications

(12 citation statements)

References 5 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…For example, for inorganically bonded sand cores, a bending strength range of approximately 2.5–4.0 MPa is typically assumed, while Bernhard et al report values roughly between 1 and 8 MPa measured on samples based on four different types of organic binders . For salt cores meant for use in high pressure die casting, Jelinek and Adamkova report values roughly between 0.7 and 2.3 MPa (shot cores) and 2.8 to 5.2 MPa (squeezed cores) . These values fall short by up to an order of magnitude of figures suggested by Czerwinski et al, who report bending strengths ranging from 6 to 30 MPa, depending on the actual composition of the salt core …”

Section: Resultsmentioning

confidence: 89%

“…A possible alternative are salt cores. These are, e.g., used in gravity and low pressure die casting of aluminum components, e.g., for introducing channel structures in internal combustion engine pistons, and to some degree also in high pressure die casting . The main disadvantages of salt cores are their limited strength and the need to leach them out.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

New Core Technology for Light Metal Casting

et al. 2018

View full text Add to dashboard Cite

A new concept for lost cores for gravity castings is presented. In contrast to the conventional principle of thermally breaking down binder strength, demolding of the new cores is based on a mechanical collapse of parts of the filler material. For this purpose, the usual sand filler is substituted for hollow microspheres with defined isostatic compression strength. After casting, the core is subjected to high hydrostatic pressure, leading to destruction of the hollow filler and a resulting loss of core structural strength and volume, allowing it to be washed out easily. In the present study, phosphate-, gypsum-, and cement-bonded cores with additions of hollow glass microspheres and cenospheres are produced and their bending strength and surface quality are determined. The core behavior during the casting process is evaluated using permanent mold gravity and low pressure aluminum casting experiments. Phosphate bonded materials containing 62 vol% of glass microspheres exhibit the best combination of surface quality and collapse behavior while reaching strength levels comparable to conventional sand cores. The study contributes to a deeper understanding of the collapse mechanisms, suggesting a major role of 1) open porosity of the matrix phase, 2) sufficient strength of the filler-matrix interface, and 3) filler particle shell integrity. Due to a lack of the latter, cenospheres are proved unsuitable for the new demolding approach.

show abstract

Section: Resultsmentioning

confidence: 89%

Section: Introductionmentioning

confidence: 99%

New Core Technology for Light Metal Casting

et al. 2018

View full text Add to dashboard Cite

show abstract

“…Numerous researches have proposed many kinds of new collapsible or expendable cores comprised of sand, salt, and metallic and organic material [38][39][40][41][42].…”

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Study of an Automotive Component Produced with Innovative Ceramic Core in High Pressure Die Casting (HPDC)

Cornacchia

Dioni

Faccoli

et al. 2019

Metals

View full text Add to dashboard Cite

Weight reduction and material substitution are increasing trends in the automotive industry. High pressure die casting (HPDC) is the conventional casting technology for the high volume production of light alloys; it has recently found wide application in the manufacturing of critical components, such as complex and thin geometry automotive parts. However, the major restriction of this affordable technology is the difficulty to design and realize hollow sections or components with undercuts. An innovative way to further increase the competitiveness of HPDC is to form complex undercut shaped parts through the use of new lost cores that are able endure the high pressures used in HPDC. This paper investigates the use of innovative ceramic lost cores in the production of a passenger car aluminum crossbeam by HPDC. Firstly, process and structural simulations were performed to improve the crossbeam design and check the technology features. The results led to the selection of the process parameters and the production of some prototypes that were finally characterized. These analyses demonstrate the feasibility of the production of hollow components by HPDC using ceramic cores.

show abstract

“…1) Many high-strength salt cores have therefore been proposed for use in high-pressure die-casting. For example, Yaokawa et al 2) proposed composites of salts and ceramics, and Jelínek and Adámková 3) proposed the NaCl or KCl cores by high-pressure squeezing using alkali silicate. Our group has previously presented high-strength salt-mixture cores of the KClNaClK 2 CO 3 Na 2 CO 3 system made by gravity casting.…”

Section: Introductionmentioning

confidence: 99%

High-Temperature Mechanical Properties of NaCl–Na<sub>2</sub>CO<sub>3</sub> Salt-Mixture Removable Cores for Aluminum Die-Casting

et al. 2019

View full text Add to dashboard Cite

The NaClNa 2 CO 3 salt mixture is proposed as a water-soluble core material for aluminum die-casting processes. The mechanical properties and microstructures of NaClNa 2 CO 3 samples prepared by gravity casting were investigated. The salt mixtures had superior properties compared to those of the pure salts. Plastic deformation occurred during compression tests at high temperatures because the eutectic region changed from lamellar to granular. Salt mixtures with NaCl primary phase and eutectic regions were found to be the most suitable core material.

show abstract

Lost Cores for High-Pressure Die Casting

Cited by 22 publications

References 5 publications

New Core Technology for Light Metal Casting

New Core Technology for Light Metal Casting

Experimental and Numerical Study of an Automotive Component Produced with Innovative Ceramic Core in High Pressure Die Casting (HPDC)

High-Temperature Mechanical Properties of NaCl–Na<sub>2</sub>CO<sub>3</sub> Salt-Mixture Removable Cores for Aluminum Die-Casting

Contact Info

Product

Resources

About