High Integrity Die Casting Processes by Edward J. Vinarcik

By Edward J. Vinarcik

"It's approximately time training engineer with casting and educational event has written a e-book that gives solutions to questions on squeeze casting and semi-solid molding/forming that many engineers and scholars of casting desire answered.-Joseph C. Benedyk, PhDConsultant and retired technical director, AlcoaHigh Integrity Die Casting tactics offers a finished examine the options at the back of complicated die casting applied sciences, together with vacuum die casting, squeeze casting, and a number of other editions of semi-solid metalworking. sensible purposes for those strategies are illustrated in several case studies.This single-source reference instrument provides the most recent fabric in 5 sections:* easy options of die casting and molten steel circulate* excessive integrity die casting tactics with case reviews* Product layout concerns* Controlling caliber and fending off defects* destiny advances below developmentKey insurance features a survey of liquid steel movement, ideas to beat the restrictions of conventiona"

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1 Comparison of (a) laminar flow and (b) turbulent flow. flow of a fluid with specific properties in a conduit with a specific geometry, a critical velocity exists below which the flow is laminar and above which the flow is turbulent. 2 graphically presents the experiments conducted by Reynolds in which a colored dye was injected into a liquid flowing in a glass tube. 2a. 2b), the colored dye rapidly broke up and mixed with the fluid from its point of injection. 2 Illustration of the experiment demonstrating the difference between (a) laminar flow and (b) turbulent flow.

3 FLOW AT THE METAL FILL FRONT Although an understanding of the bulk liquid metal flow is often useful, the flow of the metal at the fill front is of most concern. Three distinct metal fill fronts are encountered in die casting pro- 16 MOLTEN METAL FLOW IN HIGH INTEGRITY DIE CASTING PROCESSES cesses: planar fill, nonplanar fill, and atomized fill. Each of these phenomena will be discussed separately in this section. Traditional thinking regarding fluid flow tends to assume that the liquid metal fill front progresses as a uniform plane throughout the die.

ERC / NSM-UIRS-92-17, The Ohio State University Engineering Research Center for Net Shape Manufacturing, October 1992. 9. , A Method for Predicting Porosity in Die Castings, Technical Brief No. ERC / NSM-TB-91-04C, The Ohio State University Engineering Research Center for Net Shape Manufacturing, September 1991. 1 INTRODUCTION Many of the defects and problems encountered when producing components using the conventional die casting process stem from the type of liquid metal flow within the die cavity.

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