High Integrity Die Casting Processes

Basic concepts of die casting and molten metal flow. High integrity die casting processes with case studies. Product design considerations Controlling quality and avoiding defects. Future advances under development.

High Integrity Die Casting Processes

Edward J. Vinacrik

John Wiley & Sons

2018

Abstract

High Integrity Die Casting Processes provides a comprehensive look at the concepts behind advanced die casting technologies, including vacuum die casting, squeeze casting, and several variants of semi-solid metalworking. Practical applications for these processes are illustrated in numerous case studies.

This single-source reference tool presents the latest material in five sections:

Basic concepts of die casting and molten metal flow
High integrity die casting processes with case studies
Product design considerations
Controlling quality and avoiding defects
Future advances under development

CONTENTS

INTRODUCTION.

1 Introduction to High Integrity Die Casting Processes.

2 Molten Metal Flow in High Integrity Die Casting Processes.

HIGH INTEGRITY DIE CASTING PROCESSES.

3 Vacuum Die Casting.

Case Studies: Vacuum Die Casting.

4 Squeeze Casting.

Case Studies: Squeeze Casting.

5 Semi-Solid Metalworking.

Case Studies: Aluminum Semi-Solid Metalworking.

Case Studies: Magnesium Semi-Solid Metalworking.

6 Thermal Balancing and Powder Die Lubricant Processes.

DESIGN CONSIDERATIONS FOR HIGH INTEGRITY DIE CASTINGS.

7 Design for Manufacturability of High Integrity Die Castings.

8 Component Integration Using High Integrity Die Casting Processes.

9 Value Added Simulations of High Integrity Die Casting Processes.

CONTROLLING QUALITY IN HIGH INTEGRITY DIE CASTING PROCESSES.

10 Applying Statistical Process Control to High Integrity Die Casting Processes.

11 Defects in High Pressure Casting Processes.

VISIONS OF THE FUTURE.

12 Future Developments in High Integrity Die Casting.

STUDY QUESTIONS.

Appendix A: Common Nomenclature Related to High Integrity Die Casting Processes.

Appendix B: Recommended Reading.

B.1 Books.

B.2 Papers.

B.3 Periodicals.

Appendix C: Material Properties of Aluminum.

Appendix D: Die Cast Magnesium Material Properties.

High Integrity Die Casting Processes is a valuable reference for both component producers and component users alike. Process engineers, tool designers, manufacturing engineers, production managers, and machine operators will acquire a better understanding of these advanced die casting processes to optimize manufacturing and improve product quality. Component designers, product engineers, purchasing agents, buyers, supplier quality engineers, and project managers will gain insight into these processes and develop superior products by design.