High Integrity Die Casting Processes
High Integrity Die Casting Processes
ISBN: 978-0-471-27546-6 October 2002 256 Pages
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—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.
Table of contents
Figures and Tables.
1 Introduction to High Integrity Die Casting Processes.
2 Molten Metal Flow in High Integrity Die Casting Processes.
HIGH INTEGRITY DIE CASTING PROCESSES.
3 Vacuum Die Casting.
Case Studies: Vacuum Die Casting.
4 Squeeze Casting.
Case Studies: Squeeze Casting.
5 Semi-Solid Metalworking.
Case Studies: Aluminum Semi-Solid Metalworking.
Case Studies: Magnesium Semi-Solid Metalworking.
6 Thermal Balancing and Powder Die Lubricant Processes.
DESIGN CONSIDERATIONS FOR HIGH INTEGRITY DIE CASTINGS.
7 Design for Manufacturability of High Integrity Die Castings.
8 Component Integration Using High Integrity Die Casting Processes.
9 Value Added Simulations of High Integrity Die Casting Processes.
CONTROLLING QUALITY IN HIGH INTEGRITY DIE CASTING PROCESSES.
10 Applying Statistical Process Control to High Integrity Die Casting Processes.
11 Defects in High Pressure Casting Processes.
VISIONS OF THE FUTURE.
12 Future Developments in High Integrity Die Casting.
Appendix A: Common Nomenclature Related to High Integrity Die Casting Processes.
Appendix B: Recommended Reading.
Appendix C: Material Properties of Aluminum.
Appendix D: Die Cast Magnesium Material Properties.
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