• Title/Summary/Keyword: Aluminum Die-Casting

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Mechanical Properties of Hyper-Eutectic Aluminum Alloys for Automobile Parts (자동차 부품용 과공정 알루미늄 합금의 기계적 특성)

  • Bae, Chul-Hong;Kim, Jong-Myung
    • Transactions of the Korean Society of Automotive Engineers
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    • v.18 no.1
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    • pp.120-126
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    • 2010
  • It was known that the excellent wear resistance of hyper eutectic aluminum alloy is based on the primary Si particles which are distributed in the base metal. When the primary Si volume fraction increases, the smaller size have excellent wear resistance characteristics. However, this trend always does not match. There is no investigation result based on the materials and methods for real using parts. In this study, using the automotive parts manufacturer currently in use hyper eutectic Al alloy tensile test specimen type sample was fabricated by 350Ton high pressure die-casting machine. Then, fluidity, tensile, impact and wear resistance properties were evaluated. If the casting quality, primary Si size, fraction and distribution are similar, mechanical properties and wear resistance are equivalent.

Characteristic Strength of $\delta$-Al$_2$O$_3$/Aluminum Composite by Rheo-compocasting (반용융 가공법에 의한 $\delta$-Al$_2$O$_3$/Aluminum 복합재료의 강도 특성)

  • 이상필;김만수;김석호;윤한기
    • Proceedings of the KWS Conference
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    • 1995.04a
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    • pp.155-159
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    • 1995
  • A16061 alloy reinforced with 10 vol% $\delta$-A1$_2$O$_3$ short fiber have been fabricated by Rheo-compocasting and squeeze casting and extruded at high temperature using conical shape die and curved shape die with various extrusion ratios.. Tensile and hardness tests were carried out to examine mechanical properties of extruded materials and SEM observation of fractured surface was capable of accounting for fracture mechanism and bonding state of fiber and matrix.

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Semi-Solid Forming, Casting and Forging Technologies of Lightweight Materials (경량화 소재의 반용융 및 주조/단조기술)

  • 강충길;최재찬;배원병
    • Journal of the Korean Society for Precision Engineering
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    • v.17 no.4
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    • pp.7-21
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    • 2000
  • This paper describes an overview of the thixoforming and thixomolding processes. Semi-solid metalworking (SSM), which is called the thixoforming process of aluminium materials, incorporates the elements of both casting and for the manufacture of near net shape parts. The SSM has some advantages such as net shape or near net shape manufacturing, the ability to form thin walls, excellent surface finish, tight tolerance, and excellent dimensional precision. The thixomolding process of Mg alloy (AZ9l) is a combination of two technologies both conventional die casting and plastic injection molding. The feed material used is a machined chip with a geometry of approximately 1 mm square and a length of 2~3 mm. The semi-solid forming (SSF) of high quality aluminium and magnesium parts will be established in the automotive and electronic industry, in the future. The hybrid method of casting/forging has been caused attention. This process uses a preformed material made by casting instead of the wrought material and finishes it by a single forging process. This process is expected to lower costs without sacrificing the mechanical and finishes it by a single forging process. The process is expected to lower costs without sacrificing the mechanical properties. The authors, intending that the casting/forging process contributes to a reduction in production cost of aluminum automotive parts in Korea, describes the feature of the casting/forging process, aluminum alloys suitable for the cast preform, microstructure and mechanical properties of the cast preform, application examples of cast/forging, and further study.

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Microstructural Modification of High-Fe Containing A356 Alloy by Liquid Metal Shearing Process (용융금속 교반공정을 통한 고Fe 함유 A356 합금의 미세조직 개질)

  • Kim, Bong-Hwan;Lee, Sang-Mok
    • Journal of Korea Foundry Society
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    • v.31 no.6
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    • pp.354-361
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    • 2011
  • The liquid metal shearing device was constructed and assembled with a commercial high-pressure die-caster in order to induce intensive turbulent shearing force on molten aluminum alloys. The effect of the liquid metal shearing on the microstructure and tensile properties of A356 alloys was investigated with the variation of iron content. The experimental results show that dendritic primary ${\alpha}$-Al phase was effectively modified into a equiaxed form by the liquid metal shearing. It was also found that the needle-like ${\beta}$-AlFeSi phase in a Fe containing A356 alloy was changed into a blocky shape resulting in the improved mechanical properties. Based on the mechanical properties, it was suggested that the iron content in A356 alloy could be more widely tolerated by utilizing the liquid metal shearing HPDC process.

Microstructure and Mechanical Property of A356 for Rheocasting Using 6-Pole Electromagnetic Stirring Casting Process (6극 전자석 전자교반 레오캐스팅에 따른 A356의 조직적 / 기계적 영향분석)

  • Kim, Baek-Gyu;Roh, Jung-Suk;Bang, Hee-Jae;Heo, Min;Park, Jin-Ha;Jeon, Chung-Hwan
    • Journal of Korea Foundry Society
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    • v.40 no.3
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    • pp.61-65
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    • 2020
  • Rheo-diecasting with stirring has been used in many material industries. As the 4th Industrial Revolution approaches the world, eco-friendly high-strength and light-weight materials become more important. Casting methods have been studied and used for aluminum-alloy automobile parts. This study carried out the effect analysis of the micro-structure and mechanical properties, such as yield/ultimate tensile strength, elongation, and hardness, of A356 using the 6-pole EMS (electro-magnetic stirring) casting process with a high electromagnetic force. As a result, the hardness and elongation of the A356 after T6 heat-treatment show a significant improvement, respectively, by 20% and 50%.

Effects of Zn and Mg Amounts on the Properties of High Thermal Conductivity Al-Zn-Mg-Fe Alloys for Die Casting (다이캐스팅용 고열전도도 Al-Zn-Mg-Fe 합금의 특성에 미치는 Zn 및 Mg 첨가량의 영향)

  • Kim, Ki-Tae;Lim, Young-Suk;Shin, Je-Sik;Ko, Se-Hyun;Kim, Jeong-Min
    • Journal of Korea Foundry Society
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    • v.33 no.3
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    • pp.113-121
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    • 2013
  • The effects of Zn and Mg amounts on the solidification characteristics, microstructure, thermal conductivity and tensile strength of Al-Zn-Mg-Fe alloys were investigated for the development of high thermal conductivity aluminium alloys for die casting. Zn and Mg amounts in Al-Zn-Mg-Fe alloys had a little effect on the liquidus / solidus temperature, the latent heat for solidification and the fluidity of Al-Zn-Mg-Fe alloys. Thermo-physical modelling of Al-Zn-Mg-Fe alloys by JMatPro program showed $MgZn_2$, AlCuMgZn and Al3Fe phases on microstructure of their alloys. Increase of Zn and Mg amounts in Al-Zn-Mg-Fe alloys resulted in gradual reduction of the thermal conductivity of their alloys. Increase of Mg amounts in Al-2%Zn-Mg-Fe alloys had little effect on the tensile strength of their alloys, but increase of Mg amounts in Al-4%Zn-Mg-Fe alloys resulted in steep increase of the tensile strength of their alloys.

Effects of Alloying Elements on the Properties of High Strength and High Thermal Conductivity Al-Zn-Mg-Fe Alloy for Die Casting (다이캐스팅용 Al-Zn-Mg-Fe 합금의 특성에 미치는 Zn 및 Mg 첨가의 영향)

  • Kim, Ki-Tae;Lim, Young-Suk;Shin, Je-Sik;Ko, Se-Hyun;Kim, Jeong-Min
    • Journal of Korea Foundry Society
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    • v.33 no.4
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    • pp.171-180
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    • 2013
  • The effects of alloying elements on the solidification characteristics, microstructure, thermal conductivity, and tensile strength of Al-Zn-Mg-Fe alloys were investigated for the development of high strength and high thermal conductivity aluminium alloy for die casting. The amounts of Zn and Mg in Al-Zn-Mg-Fe alloys had little effect on the liquidus/solidus temperature, the latent heat for solidification, the energy release for solidification and the fluidity of Al-Zn-Mg-Fe alloys. Thermo-physical modelling of Al-Zn-Mg-Fe alloys by the JMatPro program showed $MgZn_2$, AlCuMgZn and $Al_3Fe$ phases in the microstructure of the alloys. Increased amounts of Mg in Al-Zn-Mg-Fe alloys resulted in phase transformation, such as $MgZn_2{\Rightarrow}MgZn_2+AlCuMgZn{\Rightarrow}AlCuMgZn$ in the microstructure of the alloys. Increased amounts of Zn and Mg in Al-Zn-Mg-Fe alloys resulted in a gradual reduction of the thermal conductivity of the alloys. Increased amounts of Zn and Mg in Al-Zn-Mg-Fe alloys had little effect on the tensile strength of the alloys.

Effect of T6 heat treatment on the microstructure and mechanical properties of AA365 alloy fabricated by vacuum-assisted high pressure die casting (고진공 고압 다이캐스팅으로 제조된 AA365 합금의 미세조직과 기계적 특성에 미치는 T6 열처리의 영향)

  • Junhyub Jeon;Seung Bae Son;Seok-Jae Lee;Jae-Gil Jung
    • Journal of the Korean Society for Heat Treatment
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    • v.37 no.3
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    • pp.121-127
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    • 2024
  • We investigate the effect of T6 heat treatment on the microstructure and mechanical properties of AA365 (Al-10.3Si-0.37Mg-0.6Mn-0.11Fe, wt.%) alloy fabricated by vacuum-assisted high pressure die casting by means of thermodynamic calculation, X-ray diffraction, scanning and transmission electron microscopy, and tensile tests. The as-cast alloy consists of primary Al (with dendrite arm spacing of 10~15 ㎛), needle-like eutectic Si, and blocky α-AlFeMnSi phases. The solution treatment at 490 ℃ induces the spheroidization of eutectic Si and increase in the fraction of eutectic Si and α-AlFeMnSi phases. While as-cast alloy does not contain nano-sized precipitates, the T6-treated alloy contains fine β' and β' precipitates less than 20 nm that formed during aging at 190℃. T6 heat treatment improves the yield strength from 165 to 186 MPa due to the strengthening effect of β' and β' precipitates. However, the β' and β' precipitates reduce the strain hardening rate and accelerate the necking phenomenon, degrading the tensile strength (from 290 to 244 MPa) and fracture elongation (from 6.6 to 5.0%). Fractography reveals that the coarse α-AlFeMnSi and eutectic Si phases act as crack sites in both the as-cast and T6 treated alloys.

Establishment of Design Criteria for Slot Shape Considering Castability of Aluminum Diecasting Process for Large Industrial Motor Rotor (대형 산업용 전동기 회전자용 알루미늄 다이캐스팅의 주조성을 고려한 슬롯 형상 설계 기준 정립)

  • Lee, Sung-Mo;Kim, Deok-Su;Park, Tae-Dong;Yoon, Young-Cheol
    • Journal of Korea Foundry Society
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    • v.36 no.1
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    • pp.10-17
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    • 2016
  • Numerical analysis has been performed to evaluate effect of the shape variables such as core length, slot width and slot length on misrun in aluminum die casting process for motor rotor. The predictive method for misrun in diecasting process was established by comparing the result of numerical analysis and an actual motor rotor. Solidification modulus was introduced to predict quantitatively the castability of aluminum diecasting process for motor rotor. It was found that there are minimum critical solidification modulus and slot width to prevent misrun according to core length through diecasting limit diagram proposed using the predictive method. The critical solidification modulus and slot width increase as core length increases to prevent misrun of aluminum motor rotor in diecasting process. Based on the results, the design criteria of slot shape to prevent misrun of aluminum motor rotor with various core length were established.