HIGH INTEGRITY DIE CASTING PROCESSES

By M. MAUNK

CONTENTS INTRODUCTION INTRODUCTION TO HIGH INTEGRITY DIE CASTING PROCESSES ORIGINS OF HIGH PRESSURE DIE CASTING CONVENTIONAL HIGH PRESSURE DIE CASTING PROBLEMS WITH CONVENTIONAL DIE CASTING STRATEGIES TO IMPROVE DIE CASTING CAPABILITIES HIGH INTEGRITY DIE CASTING PROCESSES REFERENCES MOLTEN METAL FLOW IN HIGH INTEGRITY DIE CASTING PROCESSES INTRODUCTION FLOW WITHIN A FLUID FLOW AT THE METAL FILL FRONT METAL FLOW IN VACUUM DIE CASTING METAL FLOW IN SQUEEZE CASTING METAL FLOW IN SEMI-SOLID METALWORKING PREDICTING METAL FLOW IN HIGH INTEGRITY DIE CASTING PROCESSES VACUUM DIE CASTING VACUUM DIE CASTING DE?NED MANAGING GASES IN THE DIE MANAGING SHRINKAGE IN THE DIE ELEMENTS OF VACUUM DIE CASTING MANUFACTURING EQUIPMENT APPLYING VACUUM DIE CASTING CASE STUDIES: VACUUM DIE CASTING B POST TRANSMISSION COVER ENGINE COMPONENT MOUNTING BRACKET MARINE ENGINE LOWER MOUNTING BRACKET REFERENCE SQUEEZE CASTING SQUEEZE CASTING DE?NED ELEMENTS OF SQUEEZE CASTING MANUFACTURING EQUIPMENT APPLYING SQUEEZE CASTING CASE STUDIES: SQUEEZE CASTING STEERING KNUCKLE VALVE HOUSING STEERING COLUMN HOUSING HIGH PERFORMANCE ENGINE BLOCK SEMI-SOLID METALWORKING SEMI-SOLID METALWORKING DE?NED MICROSTRUCTURES IN SEMI-SOLID METALWORKING SEMI-SOLID METALWORKING EQUIPMENT BILLET-TYPE INDIRECT SEMI-SOLID METALWORKING THIXOMOLDING DIRECT SEMI-SOLID METALWORKING APPLYING SEMI-SOLID METALWORKING CASE STUDIES: ALUMINUM SEMI-SOLID METALWORKING FUEL RAILS CONTROL ARM SWIVEL BRACKET IDLER HOUSING CASE STUDIES: MAGNESIUM SEMI-SOLID METALWORKING AUTOMOTIVE SEAT FRAME WIRELESS TELEPHONE FACE PLATES VIDEO PROJECTOR CASE CAMERA HOUSING LAPTOP COMPUTER CASE POWER HAND TOOL HOUSING THERMAL BALANCING AND POWDER DIE LUBRICANT PROCESSES THERMAL CYCLING INHERENT TO HIGH INTEGRITY DIE CASTING PROCESSES HEAT CHECKING AND SOLDERING CONTAINING THE EFFECTS OF HEAT CHECKING AND SOLDERING REPERCUSSION OF HEAT CHECKING AND SOLDERING CONTAINMENT ACTIONS THERMAL MANAGEMENT OF HIGH INTEGRITY DIE CASTING PROCESS TOOLING MINIMIZATION OF THERMAL CYCLING EFFECTS WITH POWDER LUBRICANTS APPLYING THERMAL MANAGEMENT METHODS IN REAL WORLD APPLICATIONS DESIGN CONSIDERATIONS FOR HIGH INTEGRITY DIE CASTINGS DESIGN FOR MANUFACTURABILITY OF HIGH INTEGRITY DIE CASTINGS INTRODUCTION TO DESIGN FOR MANUFACTURABILITY HIGH INTEGRITY DIE CASTING DESIGN FOR MANUFACTURABILITY GUIDELINES AUTOMOTIVE FUEL RAIL CASE STUDY REVIEW FUEL RAIL FUNCTIONAL REQUIREMENTS CASE STUDY ANALYSIS METHOD REVIEW OF THE Z-1 FUEL RAIL DESIGN REVIEW OF THE Z-2 FUEL RAIL DESIGN FURTHER DESIGN FOR MANUFACTURABILITY IMPROVEMENTS CONCLUSIONS OF THE CASE STUDY COMPONENT INTEGRATION USING HIGH INTEGRITY DIE CASTING PROCESSES INTRODUCTION TO COMPONENT INTEGRATION HIDDEN COSTS IN EVERY COMPONENT ANALYZING INTEGRATION POTENTIAL COMPONENT INTEGRATION CASE STUDY VALUE ADDED SIMULATIONS OF HIGH INTEGRITY DIE CASTING PROCESSES INTRODUCTION TO APPLIED COMPUTER SIMULATIONS COMPUTER SIMULATIONS OF HIGH INTEGRITY DIE CASTING PROCESSES APPLYING SIMULATIONS EFFECTIVELY RESOURCES PLANNING COUPLING PRODUCT AND PROCESS SIMULATIONS COMMITMENT A CASE FOR SHARING SIMULATION DATA ACROSS ORGANIZATIONS CONTROLLING QUALITY IN HIGH INTEGRITY DIE CASTING PROCESSES APPLYING STATISTICAL PROCESS CONTROL TO HIGH INTEGRITY DIE CASTING PROCESSES INTRODUCTION TO STATISTICAL PROCESS CONTROL SPC CHARACTERISTIC TYPES SPC APPLIED TO DYNAMIC PROCESS CHARACTERISTICS DIE SURFACE TEMPERATURE CASE STUDY APPLYING SPC TO HIGH INTEGRITY DIE CASTING PROCESSES DEFECTS IN HIGH PRESSURE CASTING PROCESSES CONVENTIONAL DIE CASTING DEFECTS SURFACE DEFECTS INTERNAL DEFECTS DIMENSIONAL DEFECTS DEFECTS OCCURRING DURING SECONDARY PROCESSING DEFECTS UNIQUE TO SQUEEZE CASTING AND SEMI-SOLID METALWORKING CONTAMINANT VEINS PHASE SEPARATION PREDICTING DEFECTS VISIONS OF THE FUTURE FUTURE DEVELOPMENTS IN HIGH INTEGRITY DIE CASTING CONTINUAL DEVELOPMENT NEW HIGH INTEGRITY DIE CASTING PROCESS VARIANTS RE?NEMENTS OF MAGNESIUM ALLOYS EMERGING ALLOYS FOR USE WITH HIGH INTEGRITY DIE CASTING PROCESSES METAL MATRIX COMPOSITES FOR USE WITH HIGH INTEGRITY DIE CASTING PROCESSES REDUCING TOOLING LEAD TIMES LOST-CORE TECHNOLOGIES CONTROLLED POROSITY INNOVATIONS CONTINUE STUDY QUESTIONS