High integrity die casting processes

Title:

Personal Author:

Vinarcik, Edward J.

Publication Information:

New York : John Wiley, 2003

Physical Description:

1 CD-ROM ; 12 cm

ISBN:

9780471201311

General Note:

Accompanies text with the same title : (TS239 V56 2003)

Subject Term:

Die-casting

Available:*

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"It's about time that a practicing engineer with casting and academic experience has written a book that provides answers to questions about squeeze casting and semi-solid molding/forming that many engineers and students of casting need answered."
--Joseph C. Benedyk, PhD, Consultant and retired technical director, Alcoa

High Integrity Die Casting Processes provides a comprehensive look at the concepts behind advanced die casting technologies, including vacuum die casting, squeeze casting, and several variants of semi-solid metalworking. Practical applications for these processes are illustrated in numerous case studies.

This single-source reference tool presents the latest material in five sections:

Basic concepts of die casting and molten metal flow High integrity die casting processes with case studies Product design considerations Controlling quality and avoiding defects Future advances under development

Key coverage includes a survey of liquid metal flow, strategies to overcome the limitations of conventional die casting, and potential defects unique to high integrity die casting processes. Also featured are methods for minimizing porosity, reducing cost by design, practical applied statistical process control techniques, designing for manufacturability, and containment methods for potential processing defects. Several chapters present detailed real-world examples illustrating the broad range of applications possible using high integrity die casting processes.

Included with this book is a CD-ROM containing PowerPoint(r) presentations for each chapter. These presentations can be used for training purposes in conjunction with numerous study questions designed to practically apply the content of the book to real-world situations. Selected PowerPoint(r) slides can be used to support engineering proposals, marketing presentations, or customer education seminars.

High Integrity Die Casting Processes is a valuable reference for both component producers and component users alike. Process engineers, tool designers, manufacturing engineers, production managers, and machine operators will acquire a better understanding of these advanced die casting processes to optimize manufacturing and improve product quality. Component designers, product engineers, purchasing agents, buyers, supplier quality engineers, and project managers will gain insight into these processes and develop superior products by design.

Author Notes

EDWARD J. VINARCIK, PE, is a product engineer working for a major tier 1 automotive supplier.

Preface	p. xv
Figures and Tables	p. xvii
Introduction	p. 1
1 Introduction to High Integrity Die Casting Processes	p. 3
1.1 Origins of High Pressure Die Casting	p. 3
1.2 Conventional High Pressure Die Casting	p. 5
1.3 Problems with Conventional Die Casting	p. 7
1.4 Strategies to Improve Die Casting Capabilities	p. 10
1.5 High Integrity Die Casting Processes	p. 10
References	p. 11
2 Molten Metal Flow in High Integrity Die Casting Processes	p. 13
2.1 Introduction	p. 13
2.2 Flow within a Fluid	p. 13
2.3 Flow at the Metal Fill Front	p. 15
2.4 Metal Flow in Vacuum Die Casting	p. 19
2.5 Metal Flow in Squeeze Casting	p. 21
2.6 Metal Flow in Semi-Solid Metalworking	p. 22
2.7 Predicting Metal Flow in High Integrity Die Casting Processes	p. 24
References	p. 24
High Integrity Die Casting Processes	p. 27
3 Vacuum Die Casting	p. 29
3.1 Vacuum Die Casting Defined	p. 29
3.2 Managing Gases in the Die	p. 29
3.3 Managing Shrinkage in the Die	p. 34
3.4 Elements of Vacuum Die Casting Manufacturing Equipment	p. 35
3.5 Applying Vacuum Die Casting	p. 40
References	p. 42
Case Studies: Vacuum Die Casting	p. 42
Introduction	p. 42
B Post	p. 43
Transmission Cover	p. 44
Engine Component Mounting Bracket	p. 45
Marine Engine Lower Mounting Bracket	p. 46
Reference	p. 49
4 Squeeze Casting	p. 51
4.1 Squeeze Casting Defined	p. 51
4.2 Managing Gases in the Die	p. 53
4.3 Managing Shrinkage in the Die	p. 54
4.4 Elements of Squeeze Casting Manufacturing Equipment	p. 56
4.5 Applying Squeeze Casting	p. 57
References	p. 58
Case Studies: Squeeze Casting	p. 58
Introduction	p. 58
Steering Knuckle	p. 60
Valve Housing	p. 61
Steering Column Housing	p. 62
High Performance Engine Block	p. 63
References	p. 65
5 Semi-Solid Metalworking	p. 67
5.1 Semi-Solid Metalworking Defined	p. 67
5.2 Managing Gases in the Die	p. 70
5.3 Managing Shrinkage in the Die	p. 70
5.4 Microstructures in Semi-Solid Metalworking	p. 71
5.5 Semi-Solid Metalworking Equipment	p. 72
5.5.1 Billet-Type Indirect Semi-Solid Metalworking	p. 73
5.5.2 Thixomolding Direct Semi-Solid Metalworking	p. 79
5.6 Applying Semi-Solid Metalworking	p. 82
References	p. 83
Case Studies: Aluminum Semi-Solid Metalworking	p. 84
Introduction	p. 84
Fuel Rails	p. 84
Control Arm	p. 88
Swivel Bracket	p. 89
Idler Housing	p. 90
References	p. 91
Case Studies: Magnesium Semi-Solid Metalworking	p. 91
Introduction	p. 91
Automotive Seat Frame	p. 93
Wireless Telephone Face Plates	p. 95
Video Projector Case	p. 96
Camera Housing	p. 97
Laptop Computer Case	p. 97
Power Hand Tool Housing	p. 98
References	p. 100
6 Thermal Balancing and Powder Die Lubricant Processes	p. 101
6.1 Thermal Cycling Inherent to High Integrity Die Casting Processes	p. 101
6.2 Heat Checking and Soldering	p. 102
6.3 Containing the Effects of Heat Checking and Soldering	p. 103
6.4 Repercussion of Heat Checking and Soldering Containment Actions	p. 105
6.5 Thermal Management of High Integrity Die Casting Process Tooling	p. 105
6.6 Minimization of Thermal Cycling Effects with Powder Lubricants	p. 106
6.7 Applying Thermal Management Methods in Real World Applications	p. 108
References	p. 109
Design Considerations for High Integrity Die Castings	p. 111
7 Design for Manufacturability of High Integrity Die Castings	p. 113
7.1 Introduction to Design for Manufacturability	p. 113
7.2 High Integrity Die Casting Design for Manufacturability Guidelines	p. 113
7.3 Automotive Fuel Rail Case Study Review	p. 114
7.3.1 Fuel Rail Functional Requirements	p. 115
7.3.2 Case Study Analysis Method	p. 115
7.3.3 Review of the Z-1 Fuel Rail Design	p. 116
7.3.4 Review of the Z-2 Fuel Rail Design	p. 118
7.3.5 Further Design for Manufacturability Improvements	p. 121
7.4 Conclusions of the Case Study	p. 122
References	p. 123
8 Component Integration Using High Integrity Die Casting Processes	p. 125
8.1 Introduction to Component Integration	p. 125
8.2 Hidden Costs in Every Component	p. 125
8.3 Analyzing Integration Potential	p. 127
8.4 Component Integration Using High Integrity Die Casting Processes	p. 127
8.5 Component Integration Case Study	p. 129
References	p. 130
9 Value Added Simulations of High Integrity Die Casting Processes	p. 131
9.1 Introduction to Applied Computer Simulations	p. 131
9.2 Computer Simulations of High Integrity Die Casting Processes	p. 134
9.3 Applying Simulations Effectively	p. 136
9.3.1 Resources	p. 138
9.3.2 Planning	p. 139
9.3.3 Coupling Product and Process Simulations	p. 140
9.4 Commitment	p. 140
9.5 A Case for Sharing Simulation Data across Organizations	p. 140
References	p. 141
Controlling Quality in High Integrity Die Casting Processes	p. 143
10 Applying Statistical Process Control to High Integrity Die Casting Processes	p. 145
10.1 Introduction to Statistical Process Control	p. 145
10.2 SPC Characteristic Types	p. 148
10.3 SPC Applied to Dynamic Process Characteristics	p. 149
10.4 Die Surface Temperature Case Study	p. 151
10.5 Applying SPC to High Integrity Die Casting Processes	p. 154
References	p. 155
11 Defects in High Pressure Casting Processes	p. 157
11.1 Introduction	p. 157
11.2 Conventional Die Casting Defects	p. 157
11.2.1 Surface Defects	p. 158
11.2.2 Internal Defects	p. 159
11.2.3 Dimensional Defects	p. 161
11.3 Defects Occurring during Secondary Processing	p. 161
11.4 Defects Unique to Squeeze Casting and Semi-Solid Metalworking	p. 162
11.4.1 Contaminant Veins	p. 163
11.4.2 Phase Separation	p. 165
11.5 Predicting Defects	p. 167
References	p. 168
Visions of the Future	p. 169
12 Future Developments in High Integrity Die Casting	p. 171
12.1 Continual Development	p. 171
12.2 New High Integrity Die Casting Process Variants	p. 171
12.3 Refinements of Magnesium Alloys	p. 172
12.4 Emerging Alloys for Use with High Integrity Die Casting Processes	p. 173
12.5 Metal Matrix Composites for Use with High Integrity Die Casting Processes	p. 173
12.6 Reducing Tooling Lead Times	p. 175
12.7 Lost-Core Technologies	p. 176
12.8 Controlled Porosity	p. 177
12.9 Innovations Continue	p. 178
References	p. 178
Study Questions	p. 181
Appendix A Common Nomenclature Related to High Integrity Die Casting Processes	p. 201
Appendix B Recommended Reading	p. 207
B.1 Books	p. 207
B.2 Papers	p. 208
B.3 Periodicals	p. 209
Appendix C Material Properties of Aluminum	p. 211
References	p. 211
Appendix D Die Cast Magnesium Material Properties	p. 215
Reference	p. 218
Index	p. 219

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Summary

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Author Notes

Table of Contents