Overview
FrançaisABSTRACT
Die casting is the most economical and the most widely used method for aluminum casting. It is suitable for large volume productions, especially for the automotive industry, but offers limited mechanical properties. Several variants of HPDC, vacuum HPDC, Squeeze Casting and Semi Solid Casting offer improved mechanical properties. Gravity or low pressure permanent mold casting is more costly but offer higher mechanical properties and allows for the use of sand cores.
Read this article from a comprehensive knowledge base, updated and supplemented with articles reviewed by scientific committees.
Read the articleAUTHORS
-
Michel GARAT: ESPCI engineer, private consultant, former R & D Director Aluminium Pechiney and Project Manager Rio Tinto Alcan, Peyrins, France
-
André LE NÉZET: ESF engineer, non-ferrous alloys casting expert, RENAULT, Rueil-Malmaison, France
INTRODUCTION
Casting in permanent molds (metal, cast iron or steel) makes it possible to produce a large number of parts with a single metal mold, capable of withstanding cyclic thermal shock, erosion and chemical attack (partial dissolution or tinning) resulting from contact with liquid aluminum, without deforming. The mold must have good mechanical strength, and the casting bench or machine must be able to keep it closed during the casting process (which can be carried out either by gravity or under pressure).
Aluminum casting in permanent metal molds can be divided into two main groups of processes, which for convenience we'll call die-casting and pressure die-casting.
Generally speaking, these metal mold casting processes are superior to sand casting in the following respects:
fine metallurgical structure ;
static and dynamic mechanical characteristics via the cooling rate, except in conventional die casting where the turbulence of the filling considerably degrades compactness and inclusion content;
dimensional accuracy ;
surface finish (depending on the poteyage).
These processes require very well thought-out part layouts and high-quality molds. They call for great rigor in implementation, and require the monitoring of certain parameters such as the regularity of production cycles, mold and cast metal temperatures. Al-Si alloys are by far the most suitable for these processes. Alloys that are sensitive to hot cracking, such as AlCu5 and AIMg3 to 6, can be used in moulds with adapted geometries, as can AlMg5Si2 for die-casting.
Overall, a judicious choice of alloy/process combination can satisfy the requirements of the majority of applications, and it is estimated that over 90% (by volume) of aluminum castings are produced using these permanent mold processes.
To complete this approach, readers are invited to consult the following articles:
Exclusive to subscribers. 97% yet to be discovered!
You do not have access to this resource.
Click here to request your free trial access!
Already subscribed? Log in!
The Ultimate Scientific and Technical Reference
KEYWORDS
foundry processes | die design | properties of the parts | high pressure die casting | permanent mould casting
This article is included in
Metal forming and foundry
This offer includes:
Knowledge Base
Updated and enriched with articles validated by our scientific committees
Services
A set of exclusive tools to complement the resources
Practical Path
Operational and didactic, to guarantee the acquisition of transversal skills
Doc & Quiz
Interactive articles with quizzes, for constructive reading
Aluminium alloy casting
Bibliography
Brochures and catalogs
Éditions Techniques des Industries de la Fonderie catalog and Centre Technique des Industries de la Fonderie brochures.
International bibliographic databases
Aluminium Metadex
Reviews
France
Fonderie magazine (CTIF and ATF, monthly)
Revue de Métallurgie (monthly)
Germany
Gießerei (monthly)
Gießerei-Praxis (monthly)
Gießerei Forschung (quarterly)
United States
Modern Casting (monthly)
Foundry...
Exhibitions and congresses
World
World Foundry Congress: every two years in a different country, usually at the end of the 3rd quarter.
France
Journées d'Études de l'Association Technique de Fonderie (ATF): in France, every year.
SF2M annual days organized by the French Society of Metallurgy and Materials: every year in October....
Patents
French National Institute of Industrial Property (INPI)
A large number of patents relating to aluminum alloy casting have been filed or are in the process of being filed around the world; an exhaustive list is impossible to draw up due to the constant number of filings.
To obtain information on a given subject at a given time, it is therefore advisable to contact INPI :...
Theses
BRACCINI (M.). – Optimization of castings: study of hot cracking phenomena in Al-Cu alloys. INP Grenoble (2000).
SAVELLI (S.). – Identification of mechanisms and quantitative approach to fatigue of model aluminum casting alloys. INSA Lyon (2000).
EVANS (W.J.), JONES (H.V.), SPITTLE...
Standardization
French and European standards. French Standards Association (AFNOR)
Standards NF EN ISO
- Geometric product specification (GPS) – Dimensional and geometric tolerances for molded parts. - NF EN ISO 8062 - (2007) :
- Aluminium and aluminium...
NF EN standards
Exclusive to subscribers. 97% yet to be discovered!
You do not have access to this resource.
Click here to request your free trial access!
Already subscribed? Log in!
The Ultimate Scientific and Technical Reference