Aluminum Casting Technologies

Aluminum Casting Technologies and Cost efficacy

Aluminum is the metal of choice for the creation of light weight parts from the aerospace, automotive and transportation sectors. Casting aluminum alloys that are liquid to alloy moulds higher pressure and very low pressure die cast is a way of producing. The automotive sector of Australia supports a local aluminum die casting industry components which include transmission housings, cylinder heads, inlet manifolds and engine sumps. (

Growing in world markets such as aluminium die cast components is currently generating challenges and opportunities . Through automotive participants like Nissan and Ford and partnerships involving our study organisations, CAST has developed technologies which have benefited the productivity of our partner. Subsequently, IP that’s poised on the brink of commercialisation has been generated by these technologies. An example is CASTcoat The University of Queensland and a job that started as research. It had been developed at Castalloy, Ford, Merne Products, Nissan as well as many others with trials under job financing in CSIRO. Now it’s a technology that is provisionally. (

Cycle Time Reduction

Automated Fault Detection in Aluminium Die Casting

Modelling of Fluid Flow Within a Die Cavity Using Smoothed Particle Hydrodynamics

Tailoring of CAST’s New Die Coat for GDC and LPDC

Integrated Gravity Die Design Methodology

Improved Quality Aluminium Automotive Castings

Reduction in Metal Stress from the HPDC Procedure

Cycle Time Reduction

To raise growth of high pressure die casting by reducing system cycle time.

Greater than a decrease in cycle time executed and was achieved on parts in two business partner plants. The project has included identification of opportunities to decrease time to the process cycle, adhering to the trial to show the findings and then doing research to show the theory. To be able to implement changes this required the participation of shopfloor staff. Such trials are usually in conflict with all the day to day production of components and just through collaboration that is authentic is it possible to get the project aims.

The next year of the project has proven the growth of collaboration between researchers and industrial partners in which the research findings have been implemented from Nissan and Ford. The changes have been executed as part of this process providing cost benefits.

A good example of execution is a decrease in cycle period at Nissan to a gearbox side cover generated at a cavity die that’s revealed manufacturing outcomes that are successful from an cycle time of 75 minutes over several months down to 60 minutes. Research at Ford on a converter home projecting has revealed successful execution of cycle time reduction to 74 minutes in 90 minutes.

We will search for the casting industry generally along with opportunities with stakeholders, to execute the installation of cycle time reduction along with parts and machines.

Automated Fault Detection in Aluminium Die Casting

To develop and execute an automated fault detection system for both sub-surface and surface defects.

A fault detection system named a prototype system is prepared for extended trials and CASTvision was developed. This project is in its third season and results are emerging. The results in the algorithm, that was created and developed throughout this project’s year, have now been put to the test this past past year. The CAST staff developed a system and have designed. For Ford’s converter home casting the system could detect and discriminate between pieces that are superior and faulty. The model system is effective at identifying holes that are obstructed with this casting on some of the holes. In which shuts and tears could be discovered on Ford sump casting, systems also have been developed.

Work at Nissan in their pump cover projecting has caused a CASTvision prototype method for fault detection. The machine can capture pictures and identify categories of flaws on the part’s surface. This project has shown that improvements in machine vision could be obtained in the concept phase through to a prototype that was functioning successfully. The next step for this endeavor would be to take the theories to part systems able to manage shapes and complex shapes from part. This result is going to be a strong candidate for future commercialisation.

Modelling of Fluid Flow Within a Die Cavity Using Smoothed Particle Hydrodynamics

To create a simulation method to help business in optimisation and design of goods and dies.

This season has witnessed extensive developments in the Smoothed Particle Hydrodynamics (SPH) code together with testing performed to enhance the robustness and speed of modelling. Enhancements were made into the visualisation techniques used to show results from SPH’s three dimensional (3D) simulation effects. Animations and 3D SPH simulations of components from Metaldyne and Nissan showing filling patterns have been finished. Observations by employees at Nissan Casting of the filling pattern during creation of their casting were consistent with the SPH modelling forecasts.

Water analogue pictures from a perspex version of a servo piston die short pictures of an aluminum cast and cast component were finished for validation from SPH with stream forecasts. Next year, further speed enhancements and the procedure will be finished. Further improvements of the SPH code in the fields of solidification heat transfer, surface oxide forecast, robustness and speed are all intended in future work.

Tailoring of the New Die Coat for GDC and LPDC of reform

To commercialise the coat technologies for gravity and low pressure die cast and enhance die coat possessions.

Industrial trials were carried out in several gravity and pressure die casting plants. Use of a sealer improved in draft angle regions of the die its functionality. Two provisional patents covering innovations associated with are lodged.

Integrated Gravity Die Design Methodology

To create an integrated layout technique for gravity die casting that could attain optimum die stability feeding and return, and filling.

A brand new layout of feeders to deal with the origin of shrinkage porosity defects led to excellent results and has been executed on the expire of a customer. A study was performed on the usage of “squeeze pins” to decrease or eliminate shrinkage flaws in a gravity evaluation expire. The squeeze trap technique revealed that surface shrinkage related and could be removed micro shrinkage could be reduced in the locations. The squeeze snare notion was extended to include application to reduce requirement. The mechanism expire enabled the shearing of this gate with modification to generate gate widths that are varying.

The area of the methodology is best expire filling through tilt. The leaning movement can be programmed to coincide with the filling speed with adjustments in the stream region to ensure smooth flow. Real-time X-ray radiography on an evaluation does flow test expire. The impact of geometry on distortion will be explored using computer simulation which models thermal pressures in cycles that are casting.

Improved Quality Aluminium Automotive Castings

To enhance the functionality of pressure die casting operations by implementing tools that are enhanced to decrease casting flaws.

Successful development of proper tooling design and procedure control was achieved because of its low pressure die casting (LPDC) procedure to throw small automotive parts. A multi-cavity expire solidification simulation chosen and composed design. Dies of the design are being used to generate high-volume pieces. Decrease the cycle period and casting parameters were investigated to enhance the quality. Trials have been conducted die to look into the impact of projecting process and geometry parameters in castings having features of cylinder heads. As called, the trial generated castings in one area sandwiched from the sand center. Evaluation of castings created on the LPDC head study that is pseudo-cylinder perish will be finished to establish connections between procedure parameters and defects.

Reduction in Metal Stress from the HPDC Procedure

To investigate the function of metal pressure in high pressure die casting.

In the last six months of the undertaking, effort was concentrated on technologies. 1 such technology was made to absorb impact pressure spikes that the technology and cause die product quality to boost. A publication shock has been designed that utilised overflows. In absorbing influence pressure shocks upon 19, casting trials in CSIRO confirmed the efficacy of the technology. Through trials in Nissan Casting Plant the constraints of circuit functioning and valve timing were verified. A suggestion for a revamp to improve pressure reaction was put. The job completed in December 2001. For the creation of their Barra version engine sumps in 2002, the pressure parameters may be adopted by Ford Australia. Go over in order to learn further details about aluminum recycling rates.

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