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Manufacturing and automation as a recovery path toward sustainable growth
Published in Harish Hirani, Technological Innovations for Effective Pandemic Response, 2023
Casting is the most economical method to produce complex shape components (i.e., automotive, machine tools, pipe fittings, textile machinery) that would be difficult to make by other methods. Cast iron and aluminum are most commonly processed metals through this route. These metals in molten state are poured into a mold having the cavity of the desired shape so that metal takes an appropriate form on its solidification. With appropriate science of metal casting bronze, brass, steel, magnesium, zinc, etc. have also been casted [9].
Introduction
Published in Zainul Huda, Metallurgy for Physicists and Engineers, 2020
Metal Casting. Metal casting involves mold design and preparation, melting of metal in a furnace, and admitting molten metal into the mold cavity (where the metal solidifies at a controlled rate and takes the shape of the mold cavity) followed by the removal of the solidified metal (casting) from the mold. In most cases the casting is cleaned, heat treated, finished, and quality assured before shipping to market. There are a variety of different types of casting processes. The most common example of metal casting is the sand casting process (see Figure 1.5).
Electric Motor Industry and Switched Reluctance Machines
Published in Berker Bilgin, James Weisheng Jiang, Ali Emadi, Switched Reluctance Motor Drives, 2019
Die casting is a metal casting process where molten metal is injected into the die at high pressure. It is a quick and reliable process and enables low-cost mass manufacturing of induction machines. However, copper die-casting is not a feasible solution for cost sensitive applications. The melting temperature of copper (1,080°C) is much higher than aluminum (660°C). In copper die-casting, the dies should be preheated, and during the die casting process, the temperature should be controlled. In addition, the density of copper is higher than aluminum and this requires specialized tooling and higher tonnage presses [32]. This makes copper die cast induction machines a lot more expensive than aluminum die cast induction machines.
A study on the construction of die-casting production prediction model by machine learning with Taguchi methods
Published in Journal of the Chinese Institute of Engineers, 2023
Yung-Tsan Jou, Riana Magdalena Silitonga, Ronald Sukwadi
For a factory, production is an essential part. The output, type, and quality of production are crucial indicators for evaluating the quality of a product. This study uses the manufacturing parameters in the production process to predict whether there may be defects in the production and assist the operators in increasing their vigilance during inspections. Die casting is a metal casting process. Compared with other casting methods, it has many characteristics: high productivity, high precision dimensions, high mechanical strength, and thin-wall castings. It is one of the most widely used casting processes and its most common application in the automotive-related industries. Therefore, this study uses actual production data from domestic automobile manufacturing plants as the verification data to evaluate which machine learning algorithm is most suitable for the aluminum die-casting production industry.
ELF-MF occupational exposure in die-casting and electroplating workers in Korea
Published in International Journal of Occupational Safety and Ergonomics, 2020
Rajitha Kawshalya Mailan Arachchige Don, Joon-Sig Jung, Yun-Jin Lee, Seung-Cheol Hong
Electroplating uses electric current to reduce dissolved metal cations to form a thin coherent metal coating on an electrode. The electroplating plant selected in this study processes vehicle assembly parts, such as car door handles, buffers, rims and hoods. At the die-casting plant, a metal casting process is used that drives liquid metal under high pressure into a mold cavity. Die castings are mostly made from non-ferrous metals such as zinc, copper, aluminum, lead or magnesium. The die-casting plant in this study was a hot chamber plant.
Experimental investigation to study the effects of processing parameters on developed novel AM(Al-Mn) series alloy
Published in Materials and Manufacturing Processes, 2020
Sunil Dutta, Suresh Kumar Reddy Narala
To fabricate an alloy of fine microstructure, the selection of a process that ensures uniform mixing of elements in the base metal is extremely crucial. The uniform mixing is significant, as it affects the properties of the alloy. The liquid metal casting is a low-cost and most favored processing technique for the development of alloys. The liquid metal casting can be categorized into the high-pressure and gravity die-casting, sand casting, stir casting, squeeze casting, melt infiltration and spray forming.[19] Stir casting is preferred for the fabrication of alloys as it simultaneously ensures uniform mixing and melt temperature regulation.[20,21] Kumar et al.[19] reported an improvement in tensile properties of Mg alloys produced with the stir-casting. They further discussed that stir-cast Mg alloys were free from defects and porosity due to the uniform distribution of alloying elements. Further, the powders’ mixing in a liquid media comprises of three steps: (i) incorporation (ii) wetting of powder particles (iii) stirring of the melt; but, the uniform mixing of alloying elements can only be ensured in the third step, i.e., stirring of the melt. The stirring speed influences the shear rate, and the shear rate, in turn, controls the force produced in the molten mixing of materials.[22,23] Ravi et al.[24] achieved optimal mixing of alloying elements by using a stir casting process. The stirrer used with a 30° blade angle was rotated in a clockwise direction with 270–300 rpm; the authors reported that the structure in addition to uniform mixing was also free from air entrapment. Singh et al.[25] integrated vacuum mold with stir casting for attaining high wear resistance. Their findings revealed a substantial rise in wear resistance due to microstructure refinement resulting from stirring action. Correspondingly many past studies have reported the impact of holding temperature on tensile properties.[26,27] Hou et al.[28] reported the impact of holding temperature on Multiphase steel. Their result showed that an increase in holding temperature improves the mechanical property. Fan et al.[29] studied the effect of casting temperature on Al-Zn-Mg-Cu alloy. Their study featured the positive effect of increased temperature on tensile properties. Consequently, it was found essential to analyze the effect of stir casting parameters on the properties of novel AM alloy. The present study deliberates the adopted methodology for the fabrication of novel AM alloy followed by the analysis of microstructure and mechanical properties, and subsequently comparisons with the existing AM alloys.