arzoo_mos_pmetallurgical contents pt_1[1].pptx

Metallurgy contents

1. Government Engineering College sector-28,Gandhinagar Manufacturing of Aluminium pan by High Pressure Die Cast Process Department:- Metallurgy Engineering Subject:- Metallurgical Operation Seminar (3152114) Semester:- 5 Presented By:- Jahanvi Dave (210130121008) Guided By:- Dr.I.B.Dave Arzoo Bhalodiya (210130121009) Prof.D.V.Mahant 03-10-2023 Manufacturing of Aluminium pan by High Pressure Die Cast Process 1

2. Introduction to High Pressure Die Casting (HPDC) HPDC Machine and Machine Specification Die assembly for HPDC 03-10-2023 Manufacturing of Aluminium pan by High Pressure Die Cast Process 2 Contents

3. High-pressure die casting (HPDC) is particularly suitable for high production rates, and it is applied in several industrial fields. Pressure die casting is a repetitive process casting identical parts by injecting Aluminum into metal moulds at pressures in the order of 1000psi. Complex machinery and expensive tooling is required for this process. The production of high-pressure die castings begins by :- First pouring liquid metal into a steel shot sleeve. A piston accelerates quickly and transports the molten metal into a steel die . After the injection of molten metal into the steel die the solidification of the molten metal takes place. Lastly the die opens and the casted product is taken out of the die. 03-10-2023 Manufacturing of Aluminium pan by High Pressure Die Cast Process 3 Introduction to High Pressure Die Casting

4. The two types of High Pressure Die Casting Machines are:- Hot Chamber Die Casting Machine Hot chamber machines are used for alloys with low melting temperatures, such as zinc, tin, and lead. Typical injection pressures for a hot chamber die casting machine are between 1000 and 5000 psi. 03-10-2023 Manufacturing of Aluminium pan by High Pressure Die Cast Process 4 HPDC Machine and Machine Specification

5. 2. Cold chamber Die Casting Machine Cold chamber machines are used for alloys with high melting temperatures that cannot be cast in hot chamber machines because they would damage the pumping system. Such alloys include aluminum, brass, and magnesium. The typical injection pressures for a cold chamber die casting machine are between 2000 and 20000 psi. 03-10-2023 Manufacturing of Aluminium pan by High Pressure Die Cast Process 5

6. 3 03-10-2023 Manufacturing of Aluminium pan by High Pressure Die Cast Process 6 Die assembly for HPDC

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8. Die Design Easy flow of the molten metal into the die cavity Die designing in the selected material High grade tool steel is mostly used in die making It should used for 100-150000 cycles Design rules Maximum and uniform wall thickness Round corners to reduce stresses Some draft angle should be there for easy removal of the product from the die 03-10-2023 Manufacturing of Aluminium pan by High Pressure Die Cast Process 8 Die Design and Die rules

9. The selection of a material for die casting is based upon several factors including the density, melting point, strength, corrosion resistance, and cost. 03-10-2023 Manufacturing of Aluminium pan by High Pressure Die Cast Process 9 Die material

10. Defect Causes Flash Injection pressure too high Clamp force too low Unfilled sections Insufficient shot volume Slow injection Low pouring temperature Bubbles Injection temperature too high Non-uniform cooling rate Hot tearing Non-uniform cooling rate Ejector marks Cooling time too short Ejection force too high 03-10-2023 Manufacturing of Aluminium pan by High Pressure Die Cast Process 10 Possible Defects and Their Causes

11. LM2 Aluminium Casting Alloy (AL – Si10Cu2Fe) Colour Code – Red / White Casting Characteristics Fluidity – Can be cast into thin and intricate sections with ease. Pressure tightness – Suitable for leak-tight castings. Hot-tearing – Castings exhibit virtual freedom from hot-tearing. Anodizing LM2 can be anodically treated to give a protective surface of a darkish grey colour to the surfaces of die castings. However, they are not generally suitable for decorative anodizing. 03-10-2023 Manufacturing of Aluminium pan by High Pressure Die Cast Process 11 Aluminium Alloy Selection for Pan Manufacturing Chemical Composition Copper 0.7-2.5 Magnesium 0.3 max Silicon 9.0-11.5 Iron 1.0 max Manganese 0.5 max Nickel 0.5 max Zinc 2.0 max Lead 0.3 max Tin 0.2 max Titanium 0.2 max Aluminium Remainder

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