Livarski vestnik 62/2015 nr. 3
T. Trout*, K. Ripplinger*, A. Sholapurwalla**, S. Scott**, S. Mitra**, M. Diehm**; *Honda Engineering of North America, Inc., Anna, Ohio, ZDA; **ESI North America, Farmington Hills, Michigan, ZDA
Yunus TUREN, Levent ELEN, Department of Metal Casting, Karabuk University, Karabuk, Turkey
Zdenka Zovko Brodarac1, Davor Stanić2 , 1 University of Zagreb Faculty of Metallurgy, Sisak, Croatia, 2 CIMOS - P.P.C. Buzet d.o.o., Buzet, Croatia
Franc Zupanič1, Tonica Bončina1, Christian Gspan2, 1University of Maribor, Faculty of Mechanical Engineering, Maribor, Slovenia, 2Institute for Electron Microscopy and Nanoanalysis, Graz University of Technology, Graz, Austria
T. Trout*, K. Ripplinger*, A. Sholapurwalla**, S. Scott**, S. Mitra**, M. Diehm**; *Honda Engineering of North America, Inc., Anna, Ohio, ZDA; **ESI North America, Farmington Hills, Michigan, ZDA
CONVERSION OF A VACUUM-ASSIST CASTING TO A CONVENTIONALLY VENTED CASTING WITH THE AID OF CASTING SIMULATION
Abstract
In the current competitive environment, the capability to produce die casting components of high quality while at the same time reducing production cost and development times is a challenge the foundry industry faces today. Whether it is the design of a new component or redesign of existing products, computer aided modeling has proved that there are several cost savings to be gained in the process development and production stage. By eliminating product defects and reducing scrap and rework, the foundrymen can achieve improved and more consistent product quality and more efficient designs that produce higher yields.
Casting simulation provides predictive evaluation tools to be applied on the entire casting process, including filling and solidification defects, and also advanced analysis like thermal stresses & part distortion to assist in making the appropriate decisions at an early stage of the manufacturing process. The casting sequence also involves upstream steps like gating and die design operations and downstream steps like trimming, heat treatment & machining operations that will determine the main properties of the component. As a consequence these different steps will influence as well the effective performance of the part once assembled in the final product and submitted to real conditions of use.
This presentation provides an overview of latest developments, driven by the requirements from the industry with a focus on a recent work involving successful conversion of an existing vacuum-assist die casting to a conventionally vented die design at Honda Engineering of North America with the simulation expertise from ESI North America.
While vacuum assist is a potential solution to manage the air in the die cavities, there is an added cost in the vacuum components connected to the die cavity, and die machine “infrastructure” in providing the equipment to create the vacuum in the die. This case study provides an overview of the lessons learned in making the switch from a vacuum to conventional venting die design, how simulation was used to identify & correct potential defects in the casting due to the air management change, and helpful guidelines for successful implementation of conventional venting.
Casting simulation provides predictive evaluation tools to be applied on the entire casting process, including filling and solidification defects, and also advanced analysis like thermal stresses & part distortion to assist in making the appropriate decisions at an early stage of the manufacturing process. The casting sequence also involves upstream steps like gating and die design operations and downstream steps like trimming, heat treatment & machining operations that will determine the main properties of the component. As a consequence these different steps will influence as well the effective performance of the part once assembled in the final product and submitted to real conditions of use.
This presentation provides an overview of latest developments, driven by the requirements from the industry with a focus on a recent work involving successful conversion of an existing vacuum-assist die casting to a conventionally vented die design at Honda Engineering of North America with the simulation expertise from ESI North America.
While vacuum assist is a potential solution to manage the air in the die cavities, there is an added cost in the vacuum components connected to the die cavity, and die machine “infrastructure” in providing the equipment to create the vacuum in the die. This case study provides an overview of the lessons learned in making the switch from a vacuum to conventional venting die design, how simulation was used to identify & correct potential defects in the casting due to the air management change, and helpful guidelines for successful implementation of conventional venting.
na vrh
Yunus TUREN, Levent ELEN, Department of Metal Casting, Karabuk University, Karabuk, Turkey
EFFECT OF ANTIMONY ADDITIONS ON MICROSTRUCTURE AND MECHANICAL PROPERTIES OF AZ91 ALLOY
Abstract
In this study, effect of antimony addition (0.2, 0.5 and 1 wt.% Sb mass fraction) on the microstructure and mechanical properties of AZ91alloy has been studied. Addition of Sb resulted in there finement of the as-cast structure and also the formation of Mg3Sb2 intermetallic particles. The strength properties are found to increase in Sb added alloys with slight reduction in ductility.
However, the maximum strength properties are obtained with 0.5% Sb addition.
However, the maximum strength properties are obtained with 0.5% Sb addition.
na vrh
Zdenka Zovko Brodarac1, Davor Stanić2 , 1 University of Zagreb Faculty of Metallurgy, Sisak, Croatia, 2 CIMOS - P.P.C. Buzet d.o.o., Buzet, Croatia
CHARACTERIZATION OF INNOVATIVE HIGH PRESSURE DIE CASTING AlSi9MgMn ALLOY PROPERTIES
Abstract
Novel multicomponent AlSi9MgMn alloy has been investigated due to unusual chemical composition. An AlSi9MgMn alloy is the first aluminum alloy with low iron and intentionally high manganese content developed for structural automotive casting parts and sets produced by high pressure die casting process. This alloy has been characterised by enhanced mechanical properties of castings such as ductility and toughness at high cooling rates due to evolution of intermetallic AlxMnyFezSiu phase in globular manner. Characterization of novel multicomponent AlSi9MgMn alloy at high cooling rate related to high pressure die casting indicates evolution of fine intermetallic phases with globular morphology which directly influence on development of enhanced mechanical properties.
Investigation revealed evolution of characteristic microstructural constituents on the base of their morphology and chemical composition: primary aluminum (aAl) with mixed dendrite and globular morphology, complex intermetallic phase AlxMnyFezSiu in globular / polyhedron morphology, main eutectic in interdendritic spaces (aAl + bSi). Complex intermetallic phase AlxMnyFezSiu evaluated at high cooling rate reveals globular or polyhedron morphology which indicates independently evolution in early stages of solidification, due to both local undercooling and liquid composition which allow direct nucleation of the equilibrium phase in the liquid by individual nucleation and growth or by increase in thickness of that originated previously, that have been transported mainly by diffusion in the liquid.
Eutectic posses mixed lamellar and fibrous morphology. Obtained mechanical properties were very high when compared to common aluminium automotive alloys. A significant differentiation has been established due to increasing of cooling / solidification rate obtained by several sample diameters. Test samples exposed to higher cooling rate due to their geometry (smaller diameter) show increase in yield and tensile strength and elongation due to finer microstructure, prominent globular microstructure of primary aluminium, intermetallic AlxMnyFezSiu phase and completely modified fibrous eutectic.
Characterization of novel multicomponent AlSi9MgMn alloy indicates applicability of this material for safety automotive parts due to obtained high values of mechanical properties.
Investigation revealed evolution of characteristic microstructural constituents on the base of their morphology and chemical composition: primary aluminum (aAl) with mixed dendrite and globular morphology, complex intermetallic phase AlxMnyFezSiu in globular / polyhedron morphology, main eutectic in interdendritic spaces (aAl + bSi). Complex intermetallic phase AlxMnyFezSiu evaluated at high cooling rate reveals globular or polyhedron morphology which indicates independently evolution in early stages of solidification, due to both local undercooling and liquid composition which allow direct nucleation of the equilibrium phase in the liquid by individual nucleation and growth or by increase in thickness of that originated previously, that have been transported mainly by diffusion in the liquid.
Eutectic posses mixed lamellar and fibrous morphology. Obtained mechanical properties were very high when compared to common aluminium automotive alloys. A significant differentiation has been established due to increasing of cooling / solidification rate obtained by several sample diameters. Test samples exposed to higher cooling rate due to their geometry (smaller diameter) show increase in yield and tensile strength and elongation due to finer microstructure, prominent globular microstructure of primary aluminium, intermetallic AlxMnyFezSiu phase and completely modified fibrous eutectic.
Characterization of novel multicomponent AlSi9MgMn alloy indicates applicability of this material for safety automotive parts due to obtained high values of mechanical properties.
na vrh
Franc Zupanič1, Tonica Bončina1, Christian Gspan2, 1University of Maribor, Faculty of Mechanical Engineering, Maribor, Slovenia, 2Institute for Electron Microscopy and Nanoanalysis, Graz University of Technology, Graz, Austria
PRECIPITATES IN AN ALUMINIUM QUASICRYSTALLINE ALLOY
Abstract
Aluminium quasicrystalline alloys represent a novel class of high-strength alloys. They possess a great potential for practical applications in many fields. In this study, we used a quasicrystalline Al-alloy with a copper addition in order to achieve strengthening by heat treatment. The alloys were prepared by casting into a copper mould. Quasicrystals formed during solidification. They were present either as a primary phase or as a part of a quasicrystal-containing eutectic. Afterwards, the samples were subjected to T5 heat treatment. The hardness of melt-spun ribbons increased considerably, while the hardness of gravitationally cast samples did not change noticeably. Detailed investigation using transmission electron microscopy (TEM) showed that different types of precipitates can form, depending primarily on the heat treatment temperature. At lower temperatures binary Al-Cu precipitates formed, in the intermediate region prevailed the formation of quasicrystalline precipitates, while at higher temperatures formed Al20Mn3Cu2 precipitates.
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