Street Die Casting Metallurgy

Butterworths Monographs in Materials
1. Auflage 2016
ISBN: 978-1-4831-6339-0
Verlag: Elsevier Science & Techn.
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 318 Seiten, Web PDF

Die Casting Metallurgy focuses on developments in the metallurgy of die casting. Ore distribution, smelting methods, and energy requirements for the major non-ferrous metals that are die cast are considered. This text has 29 chapters; the first of which provides an overview of early developments in die casting. After explaining how metals and alloys are die cast, the book turns to the production of aluminum and its alloys, aluminum alloy die castings, and melting equipment for aluminum alloys. The chapters that follow explore the metallurgy of zinc and magnesium alloys; brass and ferrous die casting; automatic metal transfer systems; metal melting treatments; and the metallurgy of die casting machines. Developments in lubrication, die casting, and finishing processes are also considered. This book also describes pressure die casting dies, thermal fatigue of die casting dies, heat treatment of die steels, and surface treatment of steels. Some comparative alloy specifications are summarized and an attempt is made to correlate units of hardness, strength, and other properties. This book will be of interest to materials scientists and industrial materials engineers.

Dr. Kaye has been a practicing physician scientist for over 30 years. He is Vice Chancellor of Academic Affairs at LSU Health Shreveport. It has been a personal goal of his to significantly contribute to the education and development of future physicians, scientists, professors, and researchers. Dr. Kaye's laboratory has made significant scientific contributions through in vivo, prospective human clinical trials, and retrospective data review research involving anesthesiology airway devices, multimodal pain management, and novel pharmaceuticals. In 2022 he has contributed to 12 books, 44 book chapters, and 144 PubMed articles, all of which include students, residents, and faculty, and involve collaborations from different departments at LSU. Overall, he has published over 1000 PubMed articles and has authored/co-authored over 300 abstracts. Dr. Kaye has mentored hundreds of clinical fellows, residents, and faculty appointments, in addition to hundreds of medical and graduate students.

Autoren/Hrsg.

Street, Arthur

Inhaltsverzeichnis

1;Front Cover;1
2;Die Casting Metallurgy;4
3;Copyright Page;5
4;Table of Contents;8
5;Preface;6
6;Chapter 1. Early developments in die casting;10
6.1;References;18
7;Chapter 2. Die casting metals and alloys;19
7.1;The choice of alloy;21
7.2;References;24
8;Chapter 3. The production of aluminium and its alloys;26
8.1;Re-cycling of scrap;28
8.2;Secondary aluminium alloy production;29
8.3;References;31
9;Chapter 4. Aluminium alloy die castings;32
9.1;The effect of modification and rapid cooling;32
9.2;Aluminium–silicon–copper alloys;37
9.3;The effect of other elements;39
9.4;Die cast engine blocks;40
9.5;Hyper eutectic aluminium–silicon alloys;44
9.6;Aluminium–magnesium alloys;45
9.7;Other aluminium alloys;46
9.8;Castings in aluminium;47
9.9;Pressure die cast rotors;48
9.10;References;51
10;Chapter 5. Aluminium as a substitute for cast iron;53
10.1;References;55
11;Chapter 6. Silicon;56
11.1;References;58
12;Chapter 7. Melting equipment for aluminium alloys;59
12.1;Molten metal deliveries;60
12.2;Bulk melting;62
12.3;Reverberatory furnaces;62
12.4;Immersed crucible bulk melting furnace;65
12.5;Radiant roof furnaces;67
12.6;Basin tilting crucible furnaces;67
12.7;Electric induction furnaces;69
12.8;Coreless induction furnaces;70
12.9;Channel-less detachable inductor furnaces;72
12.10;Transport of molten metal to the die casting machines;73
12.11;Melting-holding furnaces;74
12.12;Furnace efficiency;74
12.13;Holding furnaces;75
12.14;References;79
13;Chapter 8. Inclusions and hard spots in aluminium alloys;80
13.1;Aluminium oxide;80
13.2;Intermetallic compounds;82
13.3;Prevention of oxide and intermetallic segregation;85
13.4;Problems of automation;86
13.5;References;88
14;Chapter 9. Zinc and zinc alloys;89
14.1;Thermal process;90
14.2;The development of zinc die casting alloys;90
14.3;References;94
15;Chapter 10. The metallurgy of zinc alloys;95
15.1;The effect of copper additions on the zinc–aluminium alloys;97
15.2;Magnesium;97
15.3;Iron;98
15.4;The effect of impurities;98
15.5;Shrinkage during normal ageing;99
15.6;Quality mark schemes for zinc alloy die castings;101
15.7;Metallurgical control in the zinc die casting plant;101
15.8;Zinc alloy manufacture at the die casting plant;102
15.9;Physical properties of zinc alloys;103
15.10;Mechanical properties;103
15.11;Properties at subnormal temperatures;104
15.12;Zinc alloy die castings in corrosive conditions;105
15.13;References;106
16;Chapter 11. Zinc alloy die castings;107
16.1;Thin-wall die casting and the new technology;112
16.2;Alloy developments;116
16.3;References;117
17;Chapter 12. Melting processes for zinc alloys;118
17.1;Central melting furnaces;118
17.2;Transport of molten zinc alloy;121
17.3;Launder systems;122
17.4;Melting of plated zinc alloy scrap;124
17.5;References;125
18;Chapter 13. Cryogenic trimming of zinc alloy die castings;126
18.1;References;130
19;Chapter 14. Low melting point alloys;131
19.1;Metallurgy of lead based alloys;133
19.2;Lead alloy die castings in batteries;135
19.3;Tin alloy die castings;138
19.4;References;139
20;Chapter 15. Magnesium and its alloys;140
20.1;The metallurgy of magnesium die casting alloys;144
20.2;Magnesium alloy die casting at Volkswagen5;146
20.3;Magnesium alloy die cast wheels;147
20.4;Other magnesium alloys;149
20.5;Pressure die casting of magnesium alloys;149
20.6;Cold chamber machines for magnesium;152
20.7;Metal dispensing for magnesium alloy;152
20.8;Metallurgical control;153
20.9;The role of beryllium in magnesium die casting;155
20.10;Metal losses;155
20.11;References;156
21;Chapter 16. Brass die casting;158
21.1;Metallurgy of die casting brasses4;159
21.2;Alloying elements;160
21.3;Brass die casting alloys;161
21.4;Die casting production;162
21.5;Dezincification;165
21.6;Zinc oxide build up;166
21.7;Metallurgical control;166
21.8;Die and core materials;167
21.9;References;168
22;Chapter 17. Ferrous die casting;170
22.1;Development of the die material;171
22.2;Cores and ejectors;172
22.3;The injection system;173
22.4;Molten metal supply;173
22.5;References;176
23;Chapter 18. Automatic metal transfer systems;177
23.1;Air pressure systems;178
23.2;Mechanical immersed pumps;180
23.3;Mechanical transfer ladles;181
23.4;Electromagnetic transfer of liquid metal;185
23.5;Vacuum feed systems;187
23.6;Other ladling methods;187
23.7;References;188
24;Chapter 19. Metal melting treatments;189
24.1;Fluxing;190
24.2;Treatment of secondary aluminium alloys;190
24.3;Metal treatments in the die casting plant;191
24.4;Zinc alloys;192
24.5;Magnesium alloys;192
24.6;Degassing;193
24.7;Fume collection and treatment;195
24.8;References;196
25;Chapter 20. The measurement of metal losses;198
25.1;Metal balance sheets;199
26;Chapter 21. The metallurgy of die casting machines;203
26.1;Shot sleeves and plungers for cold chamber machines;205
27;Chapter 22. Instrumentation;209
27.1;Metal control;211
27.2;Locking force;212
27.3;Hydraulic fluid temperature;215
27.4;Hydraulic fluids;215
27.5;Machine cycle time;216
27.6;Die temperature and die coolant;216
27.7;Internal die pressure;216
27.8;Methods of measurement;217
27.9;Furnace conditions;217
27.10;Metal analysis;218
27.11;Machine conditions;219
27.12;Plunger pressure and displacement;220
27.13;Machine locking force;223
27.14;Die temperature;224
27.15;References;225
28;Chapter 23. Lubrication developments;226
28.1;Early die face lubricants;226
28.2;The development of paste-type lubricants;227
28.3;Modern sprayable die face lubricants;228
28.4;Technology of die face lubrication;230
28.5;Die lubricant selection;231
28.6;Application of die face lubricants;232
28.7;Plunger lubricants;236
28.8;Die casting machine lubrication;237
28.9;Safety and stability of lubricants;237
28.10;Future developments;238
28.11;References;239
29;Chapter 24. New developments in die casting;240
29.1;Computer-aided die design;240
29.2;Vacuum die casting;241
29.3;Pore-free die casting;244
29.4;Die casting semisolid metals;248
29.5;References;254
30;Chapter 25. Pressure die casting dies;256
30.1;Low alloy steel and cast iron components;256
30.2;The die insert;259
30.3;Die inserts for zinc alloys;261
30.4;Electroformed die inserts;262
30.5;Dies for brass die castings;262
30.6;The cores;263
30.7;Maraging steels;264
30.8;The cooling passages;265
30.9;Ejectors;266
30.10;Refractory alloys;267
30.11;Tungsten alloys;268
30.12;Molybdenum alloys;269
30.13;Nimonics;269
30.14;References;270
31;Chapter 26. Thermal fatigue of die casting dies;271
31.1;Fatigue failure;278
31.2;References;282
32;Chapter 27. Heat treatment of die steels;283
32.1;Stress relieving;285
32.2;Preheating;286
32.3;Hardening;287
32.4;Tempering;287
32.5;Heat treatment plant;288
32.6;Vacuum heat treatment;290
32.7;References;293
33;Chapter 28. Surface treatments for steels;294
33.1;Nitriding;295
33.2;Nitrocarburizing;296
33.3;Metallizing;297
33.4;Carburizing and carbonitriding;298
33.5;References;299
34;Chapter 29. Developments in finishing processes;300
34.1;Finishes for zinc alloy die castings;300
34.2;Finishes for aluminium alloy die castings;304
34.3;Finishes for magnesium alloy die castings;306
34.4;References;308
35;Appendix : Units of Measurement;310
35.1;Temperature;310
35.2;Dimensions, and limits of accuracy;310
35.3;Weight;310
35.4;Mechanical properties;311
35.5;Proof stress;311
35.6;Pressures;311
35.7;Hardness measurements;312
35.8;Alloy specifications;313
36;Index;314