Casting Die Defect

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• Die-Cast Aluminum Squeezes Out Steel
  quot;Lighten it up" is the mantra of every automotive designer. The steering knuckles for Jaguar XJ and S-Type sedans are die cast using a proprietary P2000 HVSC (high-vacuum squeeze-casting) process. The cast-aluminum steering arms were fatigue tested by applying loads for 2.5 million cycles...
• A better way to cast aluminum
  . Permanent molds produce large numbers of dimensionally repeatable parts using molds machined from cast iron or steel. In contrast, investment and sand-cast molds are destroyed during part removal and during die casting, molten metal is injected into dies under extremely high pressures. Consequently, dies...
• Cost-Effective DieCast Components
  tooling,. This high-tech. A training pro-. trim dies, and any required secondary finishing. die casting has. fixtures. Shorter lead times can be assured. gram that never. seven external. Company-wide Quality Integration: ISO 9001. stops is a criti-. Quality assurance has moved from production. thread sets...
• voxel software
  developed a fast new method to identify potential defects that may form in die-cast metal parts for cars, major appliances, toys and electrical components. The new method analyzes part designs and locates spots where porosity or holes are likely to form during casting, weakening the material. It does...
• A Better Way to Cast Aluminum (.pdf)
  , investment and sand-cast. e. (fixed. S. s. molds are destroyed during part removal and during die. a. cost). t. n. D. casting, molten metal is injected into dies under ex-. m. e. d. i. tremely high pressures. Consequently, dies must be de-. n. e. signed to withstand these pressures which drastically. t...
• Car designers are "hip" to aluminum castings
  that pack well, such as brake calipers and steering knuckles. Bodycote says HIP works well for most investment, sand, and permanent mold (gravity die) casting. High-pressure die and lost-foam castings can, however, have surface porosity and trapped air pockets that HIP may not be able to get out...
• FEA For The Shop Floor
  flaws in the middle image, and blue shows flaws on the mesh. Predicted locations for porosity are in good agreement with observations. MSC.Marc and MSC.Dytran, nonlinear FEA programs developed by MSC.Software Corp., analyze manufacturing processes such as die casting, welding, bulk forming, profile...
• Magnesium takes on aluminum and steel
  also have lower porosity and fewer defects and, thus, better mechanical properties than die-cast magnesium. That's because Thixomolding eliminates high-velocity turbulence as molten metal enters a die. This prevents oxide and flux inclusions common with conventional casting operations. The process...
• Glossary of Forging Terms
  as mismatch. The alignment of the upper (moving) and lower (stationary) impression in the die. Die proof (cast) A casting of the die impression made to confirm the exactness of the impression. Die set The assembly of the upper and lower die shoes (punch and die holders), usually including...
• Uses and Advances of Computed Tomography in the 3D Scanning of Industrial Parts (.pdf)
  , and. The Exhaust Gas Recirculation (EGR) housing for car. becomes a competitive technology for. and truck diesel engines shown in Figure 2 was casted by. 3D scanning. TCDC. This casting won the very competitive Casting. of the Year 2007 award from The North American Die. longer than an hour...

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