Increasing Performances in High Pressure Casting Process of Aluminium Alloys

Abstract:

The purpose of this paper is to present the influence of the casting parameters in the process of producing aluminium alloy components of gearbox housing type in automotive industry. The project has as objectives the minimization of the most common casting defects met in casting of gearbox housings through adjusting the parameters of the process. In order to minimize these defects, it was studied the casting speeds in phases I and II, multiplication pressure of phase III and the mould temperature that is influenced by both the cooling channels inside the mould and the spraying process of the mould (lubrication/cooling) that helps regulate the optimum temperature. The experimental results showed that the casting defects such as pores, cast in stages, shrinkage cavities, gas holes and tightness are significantly reduced by periodically controlling and correcting the specific casting parameters.

• Periodical: Applied Mechanics and Materials (Volume 811)
• Pages: 63-74
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.811.63
• Online since: November 2015
• Authors: Eugen Madalin Galitu, George Constantin*
• Keywords: Casting, Casting Defect, Cooling, Injection Speed, Lubrication, Mould, Process

References

[1] L.A. Dobrzański, M. Krupiński, J.H. Sokolowski, P. Zarychta, A. Włodarczyk-Fligier, Methodology of analysis of casting defects, Journal of Achievements in Materials and Manufacturing Engineering, Vol. 18, Issue 1-2, September–October, (2006).

[2] M. Blair, R. Monroe, C. Beckermann, R. Hardin, K. Carlson, and C. Monroe, Predicting the Occurrence and Effects of Defects in Castings, Department of Mechanical and Industrial Engineering at the University of Iowa in Iowa City, Iowa, (2005).

DOI: 10.1007/s11837-005-0092-3

[3] P. Senthil and K. S. Amirthagadeswaran, Optimization of squeeze casting parameters for non symmetrical AC2A aluminium alloy castings through Taguchi method. Journal of Mechanical Science and Technology, (2011).

DOI: 10.1007/s12206-012-0215-z

[4] C. Cernat et all., Turnatoria de precizie (Precision Casting), Publisher Politehnica PRESS, Bucharest, (2009).

[5] R.E. Ortega Pelayo, Direct Chill and Fusion Casting of Aluminum Alloys, Thesis presented to the University of Waterloo in fulfillment of the thesis requirement for the degree of Master of Applied Science in Mechanical Engineering, Waterloo, Ontario, Canada, (2012).

[6] Catalogue: Operating instructions, Italpresse Industrie, Brescia, Italy.

[7] Catalogue: Diecast machine with cold chamber, Italpresse Industrie, Brescia, Italy.

[8] High Pressure Die Casting of Aluminium and Magnesium Alloys-Grain Structure and Segregation Characteristics, Hans Ivar Laukli, Trondheim, April, (2004).