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Aluminum Castings Engineering Guide

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by Jagan Nath (2018)

The practical guide to product and process engineering of various aluminum castings.

BRIEF CONTENTS

Chapter 1 – Aluminum Casting Applications

Introduction
Aluminum Casting Advantages and Applications
Aluminum Casting Limitations
Aluminum Casting Market Growth
Aluminum Conversions from Steel and Iron

Chapter 2 – Engineering Component Configuration

Design Development Disciplines and Interactions
Engineering of Components Design
Design and Process Validation and Production Release
Matrix of Design and Manufacturing Elements

Chapter 3 – Casting Process Options

Range of Aluminum Casting Processes
Process Cooling Rate and Microstructure
Why Sand Casting Work in Certain Aoolications

Chapter 4 – Overview of Casting Processes

Green Sand Casting Process
Air Set or No-Bake Molding Process
Vacuum Molding Process
Evaporative Foam Casting Process
Die Casting Process
Gravity Permanent Mold Process
- High-Quality Casting Capability
- Melt Treatment for Fine Microstructures
- Metal Handling to Avoid Inclusions
- High-Volume GPM Manufacturing Cell
- Solidification and Feeding to Prevent Shrink Porosity
- Semipermanent Molding
Low-Pressure Permanent Molding Process
- Directional Solidification
- Importance of Pressurization
- Oxide Prevention
- Low-Pressure Permanent Molding Cell Layout
- Low-Pressure Permanent Molding Advantages
- Use of Vacuum in Low-Pressure Permanent Molding
Counter Pressure Process
Squeeze Casting Process
Investment Casting
Rapid Prototype Casting Processes
- Rapid Prototyping System
- 3D Printing or Additive or Layered Manufacturing
- Rapid Sand Casting Process
- Rapid Die Casting Process
Cast Forge Hybrid Process
- Cast Forge Process
Semisolid Metal Processes
- Semisolid Metal
- Thixoforming
- The Slurry-on-Demand Process
- Future Opportunities for Semisolid Metal
- Further Research

Chapter 5 – Alloys and Heat Treatment Choices

Cast Alloys Designations
Alloying Elements and Alloy Characteristics
Alloys for Gravity and Low-Pressure Permanent Molds, Squeeze and Die Casting
Typical Tensile Properties of Permanent Molded Castings
Alloys for Die Castings
Typical Tensile Properties of Die Casting
Heat Treatment Designations
Typical Heat Treatment Cycles for Permanent Molded Castings
Product Functional Needs of Die Castings and Alloy Choices
Alloys for High-Vacuum Die Cast Structural Castings
Examples of Micrographs

Chapter 6 – Engineering Die Castings

Engineering Product Design
- Parting Plane
- Part Orientation
- Drafts for Aluminum Die Castings
- Shrink Factors and Linear Tolerances
- Flatness Tolerances
- Machine Stock
- Slides, Pull-backs, or Moving Cores
- Locators and Clamping Pads
- Gate Pads
- Design for Trimming
Process Engineering
- Die Casting Process Elements and Cycles Times
- Die Thermal Cycling and the Cooling Balance
- Machine Hydraulic System
- Shot Profiles and Significance of Plunger Velocities
- Significance of Fraction Solid or Solid Fraction
- Importance of Atomization
- Heat Transfer Coefficient
- Explanation of Die and Gate Temperatures
- Metal Flow Analysis
- Division of Casting into Segments
- Gating Design Guidelines
- Gating Design Steps
- Check for Machine Capability – PQ² Diagram
- Design of Runners
- Design of Overflows and Vents
- Freeze Blocks
- Computer Simulations for Flow Validation, Overflows and Vents Placement
- Vacuum Die Casting and High-Vacuum Structural Die Casting
- Local Squeeze Applications
- Quality Problem Solving

Chapter 7 – Engineering of Gravity Permanent Mold Castings

Geometric Factors of Gravity Permanent Molding
- Parting Plate and Part Orientation
- Guidelines for Parting Plane and Part Orientation
- Drafts
- Shrink Factors or Mold Maker`s Shrink Rule
- Dimension Tolerances
- Locators and Clamping Pads
- Gates and Feeder Pads
Process and Manufacturing Elements of Gravity Permanent Molding
- Mold Materials and Special Inserts
- Mold Mass, Shape, and Thickness
- Mold Alignment
- Ejection System and Mold Venting
- Quick-Change Systems for Metal Cores (Pull-Backs)
- Quick-Change Systems for Preheated Molds
Mold Coatings
- Mold Coating Materials
- Coating Application Guidelines
- Coating Thickness Control
- Cross-Hatching and Baring Out
- Mold Coatings Maps
- Mold Preparation Area Layout
Engineering of Cores and Core Boxes
- Core Box Materials
- Core Box Parting and Core Ejection
- Core Prints
- Core Blowing and Venting
- Core Carriers
- Core Mudding and Assembly
- Core Setting Fixtures and Guide Pins
- Automated Core-Setting and Auto Blow-Off
- Safety with Robotic Core-Setting
Gravity Permanent Mold Gating and Feeding Principles
- Feed Driven Castings
- Fill Driven Castings
Pouring Systems
- Importance of Pouring Volume Control
- Automated Pouring Systems
- Pouring Cup Shape and Materials
- Oxide Entrainment, Filtration, and Skimmers
- Pouring Cap Foil Removal
Mold Coating and Control
- Central Closed-Loop Water System
- Mold Cooling Schedule and Documentation
De-Coring and De-Gating
Casting Design for Heat Treatments
Cycle Time Planning and Analysis
- Tipper Cycle Planning
- Table Cycle Planning

Chapter 8 – Engineering of Low-Pressure Permanent Mold Castings

Engineering of Wheels
- Technical Requirements of Wheel
- Tooling Highlights
- Design for Directional Solidification
- Multiply Sprues for lager Wheels
- Feeding and Solidification Analysis
- Pressure Ramps
- Heat Treatment, Stacking, Aging and Curing
- Wheel Testing and Validation
Engineering of Feed-Driven Structural Casting
- Critical Safety Suspension Casting
- Front Knuckles
- Front Lower Control Arms
- Rear Lower Control Arms
- Sand-Cored Suspension Castings
Fill-Driven Chassis Castings
- Cored Lower Control Arms
- Cored and Non-Cored Cradles and Cross Members
- Gating Systems
- Distortion, Straightening and Heat Treatment

Chapter 9 – Process Selection Guidelines

Markets, Products, Processes and Alloys
Product Function and Performance Factors
- Geometric Factors
- Mechanical Properties
- Tooling Cost
- Overall Cost
General Guide for Process Selection

Chapter 10 – Product Launch Process

Development Phases and Critical Elements
Product-Process Flow Diagram
Process Failure Mode and Effects Analysis
Engineering Specifications – Example
- Example Product – Suspension Front Knuckle
- Test Procedure and Requirements
Change Control and Revalidation Requirements
Instructions and Definitions
Process Control Plan or Manufacturing Plan
- Purpose of Control Plan
Program Launch Manual