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Abstract

The paper presents the method of preparing a composite slurry composed of AlSi11 alloy matrix and 10 vol.% of SiC particles, as well as

the method of its high-pressure die casting and the measurement results concerning the castability of the obtained composite. Composite

castings were produced at various values of the piston velocity in the second stage of injection, diverse intensification pressure values, and

various injection gate width values. There were found the regression equations describing the change of castability of the examined

composite as a function of pressure die casting process parameters. The conclusion gives the analysis and the interpretation of the obtained

results.

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Authors and Affiliations

Z. Konopka
M. Łągiewka
A. Zyska
M. Nadolski
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Abstract

The measurement results concerning the abrasive wear of AlSi11-SiC particles composites are presented in paper. The method of

preparing a composite slurry composed of AlSi11 alloy matrix and 10, 20% vol.% of SiC particles, as well as the method of its highpressure

die casting was described. Composite slurry was injected into metal mould of cold chamber pressure die cast machine and

castings were produced at various values of the piston velocity in the second stage of injection, diverse intensification pressure values, and

various injection gate width values. Very good uniform arrangement of SiC particles in volume composite matrix was observed and these

results were publicated early in this journal. The kinetics of abrasive wear and correlation with SiC particles arrangement in composite

matrix were presented. Better wear resistance of composite was observed in comparison with aluminium alloy. Very strong linear

correlation between abrasive wear and particle arrangement was observed. The conclusion gives the analysis and the interpretation of the

obtained results.

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Authors and Affiliations

Z. Konopka
A. Pasieka
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Abstract

The method of pressure die casting of composites with AlSi11 alloy matrix reinforced with 10 vol. % of SiC particles and the analysis of the distribution of particles within the matrix is presented. The composite castings were produced at various values of the piston velocity in the second stage of injection, at diverse intensification pressure values, and various injection gate width values. The distribution of particles over the entire cross-section of the tensile specimen is shown. The index of distribution was determined on the basis of particle count in elementary measuring fields. The regression equation describing the change of the considered index was found as a function of the pressure die casting parameters. The conclusion presents an analysis of the obtained results and their interpretation.
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Authors and Affiliations

A. Pasieka
Z. Konopka
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Abstract

The paper presents the method of preparing a composite slurry composed of AlSi11 alloy matrix and 10 vol.% of SiC particles, as well as

the method of its high-pressure die casting and the measurement results concerning the tensile strength, the yield point, the elongation and

hardness of the obtained composite. Composite castings were produced at various values of the piston velocity in the second stage of

injection, diverse intensification pressure values, and various injection gate width values. There were found the regression equations

describing the change of mechanical properties of the examined composite as a function of pressure die casting process parameters. The

conclusion gives the analysis and the interpretation of the obtained results.

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Authors and Affiliations

Z. Konopka
A. Pasieka
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Abstract

Final quality of casts produced in a die casting process represents a correlation of setting of technological parameters of die casting cycle, properties of alloy, construction of a die and structure of gating and of bleeding systems. Suitable structure of a gating system with an appertaining bleeding system of the die can significantly influence mechanical and structural properties of a cast. The submitted paper focuses on influence of position of outfall of an gate into the cast on its selected quality properties. Layout of the test casts in the die was designed to provide filling of a shaping cavity by the melt with diverse character of flowing. Setting of input technological parameters during experiment remained on a constant level. The only variable was the position of the gate. Homogeneity represented by porosity f and ultimate strength Rm were selected to be the assessed representative quality properties of the cast. The tests of the influence upon monitored parameters were realized in two stages. The test gating system was primarily subjected to numerical tests with the utilization of a simulation program NovaFlow&Solid. Consequently, the results were verified by the experimental tests carried out with the physical casts produced during operation. It was proved that diverse placement of the gate in relation to the cast influences the mode of the melt flowing through the shaping cavity which is reflected in the porosity of the casts. The experimental test proved correlation of porosity f of the cast with its ultimate strength Rm. At the end of the paper, the interaction dependencies between the gate position, the mode of filling the die cavity, porosity f and ultimate strength Rm.

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Authors and Affiliations

J. Majerník
ORCID: ORCID
Š. Gašpár
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Abstract

Magnesium alloys are one of the lightest of all the structural materials. Because of their excellent physical and mechanical properties the

alloys have been used more and more often in various branches of industry. They are cast mainly (over 90%) on cold and hot chamber die

casting machines. One of the byproducts of casting processes is process scrap which amounts to about 40 to 60% of the total weight of a

casting. The process scrap incorporates all the elements of gating systems and fault castings. Proper management of the process scrap is

one of the necessities in term of economic and environmental aspects.

Most foundries use the process scrap, which involves adding it to a melting furnace, in a haphazard way, without any control of its content

in the melt. It can lead to many disadvantageous effects, e.g. the formation of a hard buildup at the bottom of the crucible, which in time

makes casting impossible due to the loss of the alloy rheological properties. The research was undertaken to determine the effect of an

addition of the process scrap on the mechanical properties of AZ91 and AM50 alloys. It has been ascertained that the addition of a specific

amount of process scrap to the melt increases the mechanical properties of the elements cast from AZ91 and AM50 alloys.

The increase in the mechanical properties is caused mainly by compounds which can work as nuclei of crystallization and are introduced

into the scrap from lubricants and anti-adhesive agents. Furthermore carbon, which was detected in the process scrap by means of SEM

examination, is a potent grain modifier in Mg alloys [1-3].

The optimal addition of the process scrap to the melt was determined based on the statistical analysis of the results of studies of the effect

of different process scrap additions on the mean grain size and mechanical properties of the cast parts.

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Authors and Affiliations

A. Fajkiel
P. Dudek
T. Reguła
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Abstract

Experimental Mg-Al-RE type magnesium alloys for high-pressure die-casting are presented. Alloys based on the commercial AM50

magnesium alloy with 1, 3 and 5 mass % of rare earth elements were fabricated in a foundry and cast in cold chamber die-casting

machines. The obtained experimental casts have good quality surfaces and microstructure consisting of an α(Mg)-phase, Al11RE3,

Al10RE2Mn7 intermetallic compound and small amount of α+γ eutectic and Al2RE phases.

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Authors and Affiliations

K.N. Braszczyńska-Malik
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Abstract

This paper presents the effect of the temperature and hold time in the holding furnace of 226 silumin on the characteristic quantities of

TDA curves. The temperature of phase transformations and the cooling rate were tested.It has been shown that increasing both the hold

time and the temperature in the holdingfurnace cause the decreasethe end ofα+Al9Fe3Si2+β and α+Al2Cu+βternary eutectics

crystallizationtemperature in the tested silumin. This is due to the fact an increase in amounts of impurities as a result of reacting theliquid

alloy with the gases contained in the air.It has been shown, however, that examined technological factors ofthe metal preparation do not

cause systematic changes in the cooling rate.

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Authors and Affiliations

T. Pacyniak
G. Gumienny
T. Szymczak
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Abstract

The results of investigations of defects in AME-series magnesium alloys produced by the high-pressure die-casting method are presented. The analyzed magnesium alloys contain about 5 wt% aluminum and 1-5 wt% rare earth elements introduced in the form of mischmetal. The casts were fabricated using a regular type cold-chamber high-pressure die-casting machine with a 3.2 MN locking force. The same surfaces of the casts were analyzed before and after the three-point bending test in order to determine the influence of the gas and shrinkage porosity on the deformation behavior of the alloys. The obtained results revealed that the most dangerous for the cast elements is the shrinkage porosity, especially stretched in the direction perpendicular to the that of the tensile stress action. Additionally, the influence of deformation twins arise in the dendrites of the primary α (Mg) solid solution and its interaction on the cracking process was described.
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Authors and Affiliations

Katarzyna Braszczyńska-Malik
ORCID: ORCID

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Abstract

The high pressure die casting (HPDC) is a technique that allows us to produce parts for various sectors of industry. It has a great application in such sectors as automotive, energy, medicine, as the HPDC allows us to produce parts very fast and very cheaply. The HPDC casting quality depends on many parameters. The parameters among others, are cast alloy alloy metallurgy, filling system design, casting technology elements geometry and orientation, as well as, machine operation settings. In the article, different plunger motion schemes of the HPDC machine were taken into account. Analyses lead to learning about plunger motion influence on the casting porosity and solidification process run. Numerical experiments were run with the use of MAGMASoft® simulation software. Experiments were performed for industrial casting of water pump for automotive. Main parameter taken into account was maximal velocity of the plunger in the second phase. The analysis covered porosity distribution, feeding time through the gate, temperature field during whole process, solidification time. Cooling curves of the casting in chosen points were also analysed. Obtained results allow us to formulate conclusions that connect plunger motion scheme, gate solidification time and the casting wall thickness on the solidification rate and porosity of the casting.
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Authors and Affiliations

Katarzyna Żak
1
ORCID: ORCID
Rafał Dańko
1
ORCID: ORCID
Paweł L. Żak
1
ORCID: ORCID
Wojcich Kowalczyk
2

  1. AGH University of Krakow, Faculty of Foundry Engineering, al. Mickiewicza 30, 30-059 Kraków, Poland
  2. Frech Poland Sp. z o.o., Przedmos´c, Główna 8, 46-320 Praszka, Poland
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Abstract

High-pressure die casting results in a high quality surface and good mechanical properties of castings. Under the effect of pressure, integral and solid castings are achieved without a large number of foundry defects. The correct and proper setting of technological parameters plays a very important role in minimizing casting defects. The aim of the presented article is to determine the optimum maximum piston velocity for a casting in the high-pressure casting process with two height variants, depending on their internal quality. It is because the internal quality of particular castings is important in terms of proper functionality in operations where the biggest problem is the porosity of the casting. The main cause of porosity formation is the decreasing solubility of gases (most often hydrogen) during the melt solidification. Solubility represents the maximum amount of gas that can dissolve in a metal under equilibrium conditions of temperature and pressure. Macroporosity and microporosity were determined from the sections of the surfaces in the determined zones of the castings. Here, the results was that the macroporosity decreased with increasing piston velocity. Ideal microstructure was evaluated at a piston velocity of 3 m/s for both types of castings. On the other hand, the increase in tube size has shown that velocities of 3 m/s and higher, the tube is more prone to macroporosity formation. The highest hardness was achieved at the piston velocity of 2 m/s at both tube lengths.
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Authors and Affiliations

M. Matejka
1
ORCID: ORCID
D. Bolibruchová
1
ORCID: ORCID
R. Podprocká
2

  1. University of Zilina, Faculty of Mechanical Engineering, Department of Technological Engineering, Slovak Republic
  2. Rosenberg-Slovakia s.r.o., Slovak Republic
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Abstract

The results of the Charpy impact test of AE-type magnesium alloys produced by the high pressure die casting method are presented. Three alloys with different weight fractions of rare earth elements (RE; e.g. 1, 3 and 5 wt%) and the same mass fraction of aluminium (5 wt%) were prepared. The casts were fabricated using a typical cold chamber high pressure die casting machine with a 3.8 MN locking force. Microstructural analyses were performed by means of a scanning electron microscope (SEM). The impact strength (IS) was determined using a Charpy V hammer with an impact energy equal to 150 J. The microstructure of the experimental alloys consisted of an -Mg solid solution and Al11RE3, Al10Ce2Mn7 and Al2RE intermetallic compounds. The obtained results show the significant influence of the rare earth elements to aluminium ratio on the impact strength of the investigated materials. Lower the RE/Al ratio in the chemical composition of the alloy results in a higher impact strength of the material.

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Authors and Affiliations

Katarzyna Braszczyńska-Malik
ORCID: ORCID
M.A. Malik
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Abstract

This paper presents the results of hypoeutectic 226 grade alloy as well as prepared on its basis Al-Si alloy containing Cr, V and Mo. The

additives tested were added as AlCr15, AlV10 and AlMo8 master alloys. Alloys tested were poured into DTA sampler as well as using

pressure die casting. An amount of Cr, V and Mo additives in alloy poured into DTA sampler comprised within the range approximately

0.05-0.35%. Alloys to pressure die casting contained 0.05-0.20% Cr, V and Mo. The crystallization process was examined using the derivative

thermal analysis (DTA). The microstructure of castings made in the DTA sampler as well as castings made with use of pressure die

casting were examined. The basic mechanical properties of castings made using pressure die casting were defined too. It has been shown

in the DTA curves of Al-Si alloy containing approximately 0.30 and 0.35% Cr, Mo, and V there is an additional thermal effect probably

caused by a peritectic crystallization of intermetallic phases containing the aforementioned additives. These phases have a morphology

similar to the walled and a relatively large size. The analogous phases also occur in pressure die casting alloys containing 0.10% or more

additions of Cr, V and Mo. The appearance of these phases in pressure die casting Al-Si alloys coincides with a decrease in the value of

the tensile strength Rm and the elongation A. It has been shown die castings made of Al-Si alloys containing the aforementioned additives

have a higher Rm and A than 226 alloy.

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Authors and Affiliations

G. Gumienny
T. Szymczak
T. Pacyniak
I. Stasiak
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Abstract

Development of salt cores prepared by high-pressure squeezing and shooting with inorganic binders has shown a high potential of the

given technology even for high-pressure casting of castings. Strength, surface quality of achieved castings, and solubility in water become

a decisive criterion. The shape and quality of grain surface particularly of NaCl – cooking salts that can be well applied without anticaking

additives has shown to be an important criterion. Thus the salt cores technology can cover increasingly growing demands for casting

complexity especially for the automobile industry.

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Authors and Affiliations

P. Jelínek
E. Adámková
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Abstract

The work presents the investigation results concerning the structure of composite pressure die castings with AlSi11 alloy matrix reinforced

with SiC particles. Examination has been held for composites containing 10 and 20 volume percent of SiC particles. The arrangement of

the reinforcing particles within the matrix has been qualitatively assessed in specimens cut out of the castings. The index of distribution

was determined on the basis of particle count in elementary measuring fields. The tensile strength, the yield point and elongation of the

obtained composite were measured. Composite castings were produced at various values of the piston velocity in the second stage of

injection, diverse intensification pressure values, and various injection gate width values. The regression equation describing the change of

the considered arrangement particles index and mechanical properties were found as a function of the pressure die casting parameters. The

infuence of particle arrangement in composite matrix on mechanical properties these material was examined and the functions of

correlations between values were obtained. The conclusion gives the analysis and the interpretation of the obtained results.

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Authors and Affiliations

Z. Konopka
M. Łągiewka
A. Zyska
A. Pasieka
M. Nadolski
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Abstract

This paper presents the results on the effects of die-casting process on the strength parameters of castings of the aluminium AlSi9Cu3 alloy

belonging to the group of EN AB-46000, made on renovated high pressure die-casting machine. Specimens for quality testing were taken

from the places of the casting most loaded during the service. The aim of a research was to prove how the new die-casting process control

capabilities influence on the tensile strength of the cast material defined as a value of the breaking force of the specimens. It has been

found that it is possible to specify a set of recommended settings valves of second (II) and third (III) phase, which are responsible for

filling the metal mould on die-casting pressure machine. From the point of view of the finished cast element, it was noticed that exceeding

the prescribed values of valve settings does not bring further benefits and even causes unnecessary overload and reduce the durability of

the mold. Moreover, it was noticed that reduction of the predetermined setting of the second phase (II) valve leads to the formation of

casting defects again.

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Authors and Affiliations

M. Stachowicz
Ł. Pałyga
K. Granat
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Abstract

The paper presents the results of investigations concerning the influence of negative (relative) pressure in the die cavity of high pressure

die casting machine on the porosity of castings made of AlSi9Cu3 alloy. Examinations were carried out for the VertaCast cold chamber

vertical pressure die casting machine equipped with a vacuum system. Experiments were performed for three values of the applied gauge

pressure: -0.3 bar, -0.5 bar, and -0.7 bar, at constant values of other technological parameters, selected during the formerly carried initial

experiments. Porosity of castings was assessed on the basis of microstructure observation and the density measurements performed by the

method of hydrostatic weighing. The performed investigation allowed to find out that – for the examined pressure range – the porosity of

castings decreases linearly with an increase in the absolute value of negative pressure applied to the die cavity. The negative pressure value

of -0.7 bar allows to produce castings exhibiting porosity value less than 1%. Large blowholes arisen probably by occlusion of gaseous

phase during the injection of metal into the die cavity, were found in castings produced at the negative pressure value of -0.3 bar. These

blowholes are placed mostly in regions of local thermal centres and often accompanied by the discontinuities in the form of interdendritic

shrinkage micro-porosity. It was concluded that the high quality AlSi9Cu3 alloy castings able to work in elevated temperatures can be

achieved for the absolute value of the negative pressure applied to the die cavity greater than 0.5 bar at the applied set of other parameters

of pressure die casting machine work.

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Authors and Affiliations

Z. Konopka
M. Łągiewka
A. Zyska
M. Nadolski
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Abstract

The paper presents the results of hypoeutectic silumin 226 grade and silumin produced on its basis through the addition of V and Mo.

Vanadium and molybdenum were added as the preliminary alloy AlV10 and AlMo8 in an amount providing the concentration of 0.1; 0.2;

0.3 and 0.4% V and Mo. TDA curves of tested silumins were presented; regardless of the chemical composition there were similar thermal

effects. Pressure castings microstructure research revealed the presence in silumins with the addition of V and Mo phases do not occur in

silumin without these additives. These phases have a morphology similar to the walled, and their size increases with increasing

concentration of V and Mo. The size of the precipitates of these phases silumin containing 0.1% V and Mo does not exceed 10 microns,

while 0.4% of the content of these elements increases to about 80 microns. Tests of basic mechanical properties of silumins were carried

out. It has been shown that the highest values of tensile strength Rm = 295 MPa and elongation A = 4.2% have silumin containing

approximately 0.1% V and Mo. Increasing concentrations of these elements causes a gradual lowering of the Rm and A values.

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Authors and Affiliations

T. Pacyniak
G. Gumienny
T. Szymczak
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Abstract

The paper presents the results of the application of a statistical analysis to evaluate the effect of the chemical composition of the die casting Al-Si alloys on its basic mechanical properties. The examinations were performed on the hypoeutectic Al-Si alloy type EN AC-46000 and, created on its basis, a multi-component Al-Si alloy containing high-melting additions Cr, Mo, W and V. The additions were introduced into the base Al-Si alloy in different combinations and amounts (from 0,05% to 0,50%). The tensile strength Rm; the proof stress Rp0,2; the unit elongation A and the hardness HB of the examined Al-Si alloys were determined. The data analysis and the selection of Al-Si alloy samples without the Cr, Mo, W and V additions were presented; a database containing the independent variables (Al-Si alloy's chemical composition) and dependent variables (Rm; Rp0,2; A and HB) for all the considered variants of Al-Si alloy composition was constructed. Additionally, an analysis was made of the effect of the Al-Si alloy's component elements on the obtained mechanical properties, with a special consideration of the high-melting additions Cr, Mo, V and W. For the optimization of the content of these additions in the Al-Si alloy, the dependent variables were standardized and treated jointly. The statistical tools were mainly the multivariate backward stepwise regression and linear correlation analysis and the analysis of variance ANOVA. The statistical analysis showed that the most advantageous effect on the jointly treated mechanical properties is obtained with the amount of the Cr, Mo, V and W additions of 0,05 to 0,10%.

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Authors and Affiliations

J. Szymszal
G. Gumienny
T. Szymczak
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Abstract

This article presents the results of studies in the hypoeutectic silumin destined for pressure die casting with the simultaneous addition of

chromium and tungsten. The study involved the derivative and thermal analysis of the crystallization process, metallographic analysis and

mechanical properties testing. Silumin 226 grade was destined for studies. It is a typical silumin to pressure die casting. AlCr15 and AlW8

preliminary alloys were added to silumin. Its quantity allowed to obtain 0.1, 0.2, 0.3 and 0.4% of Cr and W in the tested alloy. Studies of

the crystallization process as well as the microstructure of the silumin poured into DTA sampler allowed to state the presence of additional

phase containing 0.2% or more Cr and W. It has not occurred in silumin without the addition of above mentioned elements. It is probably

the intermetallic phase containing Cr and W. DTA studies have shown this phase crystallizes at a higher temperature range than α (Al)

solid solution. In the microstructure of each pressure die casting containing Cr and W the new phases formed. Mechanical properties tests

have shown Cr and W additives in silumin in an appropriate amount may increase its tensile strength Rm (about 11%), the yield strength

Rp0.2 (about 21%) and to a small extent elongation A.

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Authors and Affiliations

T. Pacyniak
G. Gumienny
T. Szymczak
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Abstract

The present work discusses results of increased temperature on shape-dimensional changes of a 110 type hose coupling, produced from EN AC-AlSi11 alloy with the use of pressure die casting technology. The castings were soaked for 3.5 h at temperatures 460°C, 475°C and 490°C. The verification of shape-dimensional accuracy of the elements after soaking treatment, in relation to raw casting, was carried out by comparing the 3D models received from 3D scanning. Soaking temperature of about 460°C-475°C results in no significant changes in the shapes and dimensions of the castings, or surface defects in the form of blisters, which can be seen at a temperature of 490°C.

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Authors and Affiliations

A. Jarco
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Abstract

Computational Materials Engineering (CME) is a high technological approach used to design and develop new materials including the physical, thermal and mechanical properties by combining materials models at multiple techniques. With the recent advances in technology, the importance of microstructural design in CME environments and the contribution that such an approach can make in the estimation of material properties in simulations are frequently discussed in scientific, academic, and industrial platforms. Determination of the raw material characteristics that can be modeled in a virtual environment at an atomic scale by means of simulation programs plays a big role in combining experimental and virtual worlds and creating digital twins of the production chain and the products. In this study, a new generation, alternative and effective approach that could be used to the development of Al-Si based wheel casting alloys is proposed. This approach is based on the procedure of optimizing the physical and thermodynamic alloy properties developed in a computer environment with the CME technique before the casting phase. This article demonstrates the applicability of this approach in alloy development studies to produce Al-Si alloy wheels using the low pressure die casting (LPDC) method. With this study, an alternative and economical way is presented to the alloy development studies by trial and error in the aluminum casting industry. In other respects, since the study is directly related to the automotive industry, the reduction in fuel consumption in vehicles is an expected effect, as the new alloy aims to reduce the weight of the wheels. In addition to conserving energy, reducing carbon emissions also highlights the environmental aspects of this study.
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Authors and Affiliations

T. Yağcı
1
Ü. Cöcen
1
O. Çulha
2

  1. Dokuz Eylul University, Dept. of Metallurgical and Materials Engineering, İzmir, Turkey
  2. Manisa Celal Bayar University, Dept. of Metallurgical and Materials Engineering, Manisa, Turkey
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Abstract

The presented work is aimed to deal with the influence of changes in the value of negative (relative) pressure maintained in the die

cavity of pressure die casting machine on the surface quality of pressure castings. The examinations were held by means of the

modified Vertacast pressure die casting machine equipped with a vacuum system. Castings were produced for the parameters selected

on the basis of previous experiments, i.e. for the plunger velocity in the second stage of injection at the level of 4 m/s, the pouring

temperature of the alloy equal to 640°C, and the die temperature of 150°C. The examinations were carried on for three selected values

of negative gauge pressure: - 0.03, - 0.05, and - 0.07 MPa. The quality of casting was evaluated by comparing the results of the surface

roughness measurements performed for randomly selected castings. The surface roughness was measured by means of Hommel Tester

T1000. After a series of measurements it was found that the smoothest surface is exhibited by castings produced at negative gauge

pressure value of - 0.07 MPa.

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Authors and Affiliations

Z. Konopka
M. Łągiewka
A. Zyska
M. Nadolski
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Abstract

A measuring system was developed for the measurement of ejector forces in the die casting process. When selecting the sensor technology, particular care was taken to ensure that measurements can be taken with a high sampling rate so that the fast-running ejection process can be recorded. For this reason, the system uses piezoelectric force sensors which measure the forces directly at the individual ejector pins. In this way, depending on the number of sensors, it is possible to determine both the individual ejector forces and the total ejector force. The system is expandable and adaptable with regard to the number and position of the sensors and can also be applied to real HPDC components. Automatic triggering of the measurements is also possible. In addition to the measuring system, a device and a method for in-situ calibration of the sensors have also been developed. To test the measuring system, casting experiments were carried out with a real aluminium HPDC aluminium component. The experiments showed that it is possible to measure the ejector forces with sufficient sampling rate and also to observe the process steps of filling, intensification and die opening by means of ejector forces. Experimental setup serves as a basis for future investigations regarding the influencing parameters on the ejection process.

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Authors and Affiliations

S. Krischke
S. Müller
T. Schuchardt
Y. Kouki
K. Dilger

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