Pertamakali masuk industry saya masuk di PT Honda lock Indonesia sebagai operator Die Casting sampai 2013. tp saya berdoa dan meyakinkan HR recruitment bahwa saya akan berusaha beradaptasi dengan job apa saja yg di tugaskan oleh pimpinan perusahaan. Dan hasilnya saya di percaya. Aktivitas Semangat pagi Bersyukur itu bukan hanya kita Apaitu Logam Berlubang? Logam berlubang adalah sejenis logam lembaran yang telah ditebuk atau dicop secara mekanis sehingga mempunyai lubang di permukaannya. Lubang ini terdapat dalam pelbagai bentuk dan reka bentuk. Logam berlubang juga dikenal sebagai plat berlubang, kepingan berlubang, atau layar berlubang. Tahun1921, Istilah “robot” pertama kali digunakan dalam sebuah drama berjudul “RUR” atau “Rossum’s Universal Robot” yang ditulis oleh penulis dari Ceko, Karel Capek. Secara sederhana drama ini mengkisahkan tentang manusia yang membuat robot dan pada akhirnya robot itu membunuh manusia yang membuatnya. Tahun 1941, penulis fiksi Vay Tiền Nhanh. Paduan logam yang sebagian besar terdiri dari aluminium sudah terlihat sangat banyak digunakan. Awalnya memang aluminium sangat penting dalam manufaktur kedirgantaraan sejak penggunaan pesawat penumpang diperkenalkan Boeing pada tahun 1960an silam. Dalam artikel ini kita akan bahas secara ringkas perbedaan sifat dan kegunaan material logam aluminium secara cor atau die casting dengan aluminium Die Cast. CASTING ALUMINIUM ITU APA? Pengecoran aluminium atau Aluminium casting adalah metode asli dan paling banyak digunakan untuk membentuk aluminium menjadi produk. Kemajuan teknis telah dibuat, tetapi prinsipnya tetap sama Aluminium cair dituangkan ke dalam cetakan untuk menduplikasi pola yang diinginkan. Proses pengecoran umumnya meliputi pengecoran pasir, pengecoran dewaxing, pengecoran gravitasi, pengecoran tekanan rendah, pengecoran cetakan keramik, pengecoran cetakan gipsum dan proses pengecoran lainnya. Proses die casting merupakan metode sejenis die casting bertekanan tinggi, yang diproduksi oleh mesin die casting ruang dingin. Tentu saja nilai aluminium cor yang digunakan dalam dua proses juga berbeda. Dalam GB standar nasional China, ZL mewakili kelas paduan aluminium cor dan YL mewakili kelas paduan aluminium cor. Umumnya, coran aluminium cor dapat diperkuat dengan perlakuan panas. Perlakuan panas T6 umumnya diadopsi, sedangkan die casting tidak cocok untuk perlakuan panas T6 karena sejumlah besar gas terdistribusi secara padat di dalamnya. Alasannya adalah suhu perlakuan panas T6 sangat tinggi, yaitu sekitar 15-20 derajat lebih rendah dari titik leleh paduan aluminium. Pada saat ini, gas dalam die casting akan mengembang dan dipaksa keluar dari permukaan casting, yang akan membuat permukaan die casting menjadi padat. Akibat penonjolan dot setelah gas habis, tampilan casting rusak parah dan tidak bisa digunakan. Pengecoran gravitasi paduan aluminium dan pengecoran tekanan rendah paduan aluminium termasuk dalam proses pengecoran cetakan logam. Keduanya digunakan untuk memproduksi coran aluminium. Cetakan milik cetakan logam. Baja mati kerja panas seperti H13 digunakan untuk membuat cetakan. Pengecoran gravitasi paduan aluminium dan proses pengecoran tekanan rendah paduan aluminium dapat menghasilkan merek paduan aluminium cor yang sama. Suhu penuangan dan waktu pembukaan cetakan aluminium cair serupa, dan kekompakan, kekuatan, dan sifat mekanik lainnya dari coran aluminium serupa. Masih ada perbedaan antara pengecoran gravitasi paduan aluminium dan pengecoran tekanan rendah paduan aluminium dalam prinsip pembentukan, struktur pengecoran aluminium, intensitas tenaga kerja, nomor batch, waktu pengembangan, dll, seperti yang ditunjukkan pada gambar di bawah ini Metode Prinsip Kerja Struktur Aluminum casting Intensitas pekerjaan dan keterampilan Minimum Jumlah Waktu pengerjaan Harga Mould cetakan Aluminum alloy gravity casting Tergantung pada gravitasi Kompleks dan beragam Tinggi 100 pendek murah Aluminum alloy low pressure casting Menggunakan tekanan udara dari kompresor seragam sedang 500 panjang tinggi Menurut perbandingan gambar di atas, pengecoran gravitasi paduan aluminium lebih cocok untuk produksi produk dengan banyak varietas, batch kecil, siklus pengembangan pendek dan persyaratan kualitas tinggi, sedangkan pengecoran tekanan rendah paduan aluminium cocok untuk produksi produk. dengan batch besar, ketebalan dinding tipis dan struktur yang cocok untuk proses pengecoran tekanan rendah paduan aluminium. Siklus pengembangan yang panjang kondusif untuk peningkatan teknologi produksi dalam proses produksi. Produk khas yang dihasilkan oleh proses pengecoran tekanan rendah paduan aluminium adalah pelek roda mobil. Struktur pengecoran aluminium ini sangat cocok untuk karakteristik struktural proses pengecoran tekanan rendah, dan volume produksinya sangat besar, sehingga ada cukup waktu untuk meningkatkan teknologi produksi. Produk khas yang dihasilkan oleh proses pengecoran gravitasi paduan aluminium adalah coran robot industri. Coran aluminium ini memiliki batch produksi kecil, persyaratan kualitas produk yang tinggi dan siklus pengembangan yang pendek. Hal ini diperlukan untuk menghasilkan coran aluminium berkualitas tinggi tanpa pori-pori dan lubang pasir dalam waktu yang sangat singkat. BEDA KUALITAS ALUMINIUM CASTING DAN ALUMINIUM DIE CAST Hampir tidak ada perbedaan yang signifikan saat material aluminum casting dan aluminium die-cast dipotong dengan mesin gergaji bandsaw. Namun tentu ada perbedaan kualitas rigiditas yang berbeda. Komponen aluminium dengan meknisme gravitasi mengalami penyebaran material yang kurang merata. Dibagian pojok dan sisi dari pengecoran casting aluminium secara gravitasi akan mengalami ketebalan atau ketipisan padat. Sedangkan material dengan pengerjaan die cast tentu mengalami keseragaman ketebalan. hal inilah yang membuat perbedaan penggunaan kedua metode ini. Jika anda ingin merancang mesin bahn bakar bensi bertekanan tinggi dengan komponen blok mesin dari material aluminium casting, tentu cenderung lebih rentan pecah dan retak dibandingkan dengan komponen blok mesin dengan desain serupa dari proses pengerjaan Aluminium Die Cast. Saat material aluminium dipotong atau dimarking dengan mesin laser, dengan parameter pemotongan yang baik dan konsisten, kemungkinan pantulan dapat dikurangi hingga hampir nol. Namun tetap perlu untuk dapat mencegah kerusakan pada laser saat mengembangkan kondisi atau jika terjadi kesalahan pada peralatan. Sistem pemotongan aluminium’ yang digunakan sebagian besar peralatan modern sebenarnya adalah cara untuk melindungi laser daripada teknik pemotongan yang inovatif. Sistem ini biasanya berbentuk sistem pantulan balik yang dapat mendeteksi jika terlalu banyak radiasi laser yang dipantulkan kembali melalui optik. Ini akan sering secara otomatis menghentikan laser, sebelum terjadi kerusakan besar. Tanpa sistem ini, ada risiko dengan pemrosesan aluminium karena tidak ada cara untuk mendeteksi apakah pantulan yang berpotensi berbahaya sedang terjadi. KESIMPULAN Selain itu, permukaan paduan Aluminium akan membentuk lapisan pelindung aluminium oksida putih jika dibiarkan tidak terlindungi dengan anodisasi dan/atau prosedur pengecatan yang benar. Kondisi tersebut dapat mengubah kualitas tepi potongannya, terutama Dalam lingkungan basah, korosi galvanik dapat terjadi ketika paduan aluminium ditempatkan dalam kontak listrik dengan logam lain dengan potensi korosi yang lebih positif daripada aluminium, dan terdapat elektrolit yang memungkinkan ion menukarkan. Disebut sebagai korosi logam tak sejenis, proses ini dapat terjadi sebagai eksfoliasi atau korosi antar butiran. Paduan aluminium dapat mengalami perlakuan panas yang tidak tepat dan dipengaruhi oleh cara produk akhir disimpan. Setelah proses pemotongan, jika permukaan potongan dibiarkan hampir tidak terlihat, elemen internal akan terpisah, dan logam kemudian terkorosi dari dalam ke luar. Sebagai perusahaan think tank industri tanpa henti, kami telah melayani berbagai skala industri di bidang Elektronik, Mekanik presisi, Pengalengan dan Pembotolan, Industri Berat, Farmasi dan Laboratorium. adalah platform untuk mempromosikan presisi dan efisiensi kepada para insinyur, teknisi, dan industrialis di Indonesia. Jika Anda yakin bahwa Anda memiliki jaminan kualitas dan ingin memperluas wawasan Anda, hubungi kami di Sales Source Metalextra Batam Indonesia Awalnya dipublikasikan pada24 Mei 2020 723 AM Pada industri tentunya sangat membutuhkan berbagai alat dan komponen lainnya. Yang kebanyakan terbuat dari sebuah logam dan tentunya memiliki kegunaannya masing-masing. Untuk hal ini, tentunya membutuhkan metode atau teknologi yang mampu mengubah sebuah bahan mentah, berupa logam menjadi alat atau benda yang berguna. Metode yang sangat umum digunakan adalah die casting. Dalam dunia pengecoran atau yang biasa disebut dengan, die casting adalah sebuah salah satu teknik pada pembuatan produk. Yang mana dengan berbahan utamanya sebuah logam. Nantinya akan dicairkan dalam sebuah tungku peleburan dan dituangkan pada rongga cetakan. Penasaran seperti apa itu dan bagaimana proses die casting? Simak pembahasannya lebih lengkap berikut Itu Die Casting?Alat atau mesin ini, yang bernama die casting adalah sebuah cetakan logam yang terdiri atau tersusun dari bahan utamanya berupa baja. Biasanya, proses ini disebut dengan pengecoran. Pada proses ini, die casting adalah salah satu teknik pembuatan sebuah produk dimana bahan utamanya yakni logam akan dicairkan. Setelah mengalami peleburan kemudian dituangkan pada sebuah cetakan rongga, sesuai dengan bentuk aslinya. Bahan cetakan yang digunakan umumnya bernama cetakan logam. Dengan berbahan logam, tempat cetakan ini mampu digunakan berkali-kali. Sehingga disebut sebagai cetakan permanen permanent mold.Saat pengisian logam cair pada sebuah cetakan yang telah disediakan. Selalu menggunakan sebuah sistem gravitasi. Nah, pengecorannya lebih dikenal dengan istilah gravity die casting. Apabila pengisian cairan dalam cetakan permanen, maka dilakukan dengan cara injeksi. Tekanan yang diberikan cukup tinggi, yang disebut high pressure die yang diketahui oleh umum, bahwa sifat dasarnya dari material die casting adalah mampu menarik panas hot yield strength. Tak hanya itu, mempunyai ketahanan pada proses tempering tamper resistant, konduktivitas panas baik thermal conductivity, koefisien sebuah muai panas thermal expection coefficient.Jenis Pengecoran Pada Die Casting Untuk proses pengecoran cetak tekan, termasuk pada proses cetakan permanen dengan cara injeksi logam cair kedalam rongga tekanan yang tinggi. Tekanan yang diberikan tersebut akan terus ditahan sampai seluruh cairan logam membeku. Sehingga hasil cetakan baru dapat dikeluarkan. Terdapat dua jenis pengecoran yang sangat umum digunakan dalam pembuatan benda logam. Perbedaannya berada pada prinsip lokasi tempat leburnya bahan. Lantas apa saja jenis pengecorannya, antara lain 1. Hot Chamber HCDCPada jenis alat hot chamber, adalah sebuah mesin yang meliputi melting unit dan injection unit berada dalam satu peralatan. Melting unit merupakan sebuah tempat yang menjadi sebagai tungku pencairan bahan logam. Injection unit berguna untuk memberikan tekanan yang sangat tinggi dalam proses pengecoran. Sebuah logam cair atau bahan utamanya yang ada di dalam melting unit. Akan langsung diinjeksikan pada unit injection. Pada proses ini, tekanan yang diberikan sekitar bahkan hingga psi. Proses hot chamber, silinder injeksi berada di dalam sebuah logam cair dan selalu terendam. Hal ini menyebabkan proses atau jam kerjanya menjadi minimum. Oleh sebab itu, hanya mampu memiliki atau mengerjakan dalam skala yang sangat pendek pada setiap siklusnya. Mesin ini banyak digunakan untuk pengecoran yang memiliki daya melting point atau titik leleh yang rendah. Seperti timbal ataupun seng. Dikarenakan jangka waktu kerja yang pendek membuat alat ini hanya bisa mengerjakan dengan titik leleh rendah. Apabila dipaksakan akan menyebabkan kerusakan mesin. Memiliki beberapa keunggulan yakni efek turbulensi rendah sehingga dapat mengurangi porosity. Selain itu, reaksi oksidasi dengan oksigen udara tidak ada dan mempunyai temperatur logam yang relatif stabil. Namun, pada alat ini juga memiliki kekurangan seperti biaya perawatan terbilang sangat mahal. Interaksi antara logam cair mampu menyebabkan abrasi yang mengotori logam. Selain itu, alat ini hanya dapat digunakan untuk logam yang memiliki titik leleh rendah. 2. Cold Chamber CCDCBerbeda dengan hot chamber, alat ini memiliki melting unit dan injection unit pada dua komponen yang berbeda tidak dalam satu alat. Jadi, pada alat ini logam cair perlu dituangkan terlebih dahulu pada melting unit ke ladel. Dan nantinya akan dibawa oleh mesin injection unit untuk dituangkan dan diinjeksi ke dalam die. Pada alat atau mesin jenis cold chamber, memiliki sistem injeksi logam yang hanya berkontak langsung dengan lelehan logam dalam waktu yang sebentar dan sangat singkat. Dengan begitu, sistem ini mampu bekerja atau jam kerjanya lebih tahan lama. Umumnya, pada mesin jenis ini membutuhkan sebuah tekanan yang lebih besar untuk mengisi dan menutup berbagai rongga. Biasanya, pada rongga die atau ujung plunger diberikan minyak atau pelumas. Yang mana digunakan untuk memberikan ketahanan lebih baik. Dengan begitu, diharapkan mampu meningkatkan umur material dan mengurangi kelengketan logam yang membeku. Sangat cocok digunakan untuk meleburkan suatu logam yang memiliki tingkat leleh tinggi. Sebagai contoh magnesium dan aluminium. Dikarenakan mampu bertahan dengan jam kerja yang lama, mesin ini mampu menghasilkan sebuah produk mulai dari 100 bahkan hingga 150 buah per jamnya. Peralatan Pada Mesin Die CastingPada proses die casting, sering dimanfaatkan dan digunakan dalam pembuatan komponen otomotif. Umumnya sering menghasilkan sebuah blok mesin. Hasil tersebut merupakan salah satu contoh produk dari adanya penggunaan proses die casting. Ada komponen lainnya seperti piston, pump casing, tuas rem, velg dan pada mesin pencetakan logam ini tentu disusun oleh beberapa komponen. Inilah komponen die casting adalah 1. Melting Unit Komponen pertama adalah melting unit. Yang mana menjadi sebuah wadah guna menampung logam cair. Selain dapat menampung, bagian mesin ini juga dapat mencairkan logam. Komponen ini sangatlah berperan penting dalam sistem cetak Injection UnitSelanjutnya adalah injection unit. Dalam unit ini berfungsi untuk melakukan sebuah transfer logam cair. Yang semula berada di melting unit kemudian dibawa ke dalam die. Kemudian disana dilakukan sebuah injeksi atau memberikan tekanan yang tinggi. Agar dapat mencetak atau membentuk suatu Die UnitDie unit merupakan sebuah cetakan permanen yang sangat umum terbuat dari logam. Alat ini memiliki beberapa rongga yang berguna untuk memberikan bentuk pada coran. Yang nantinya akan diisi dengan logam cair. Cetakan ini terdiri dari 2 unit lainnya, antara lian fixed die dan movable dan Kerugian Penggunaan Die CastingDalam penggunaan metode ini, sangat cocok untuk dimanfaatkan dalam pembuatan benda yang berdinding tipis. Umumnya, seperti untuk kendaraan bermotor atau otomotif, alat rumah tangga, peralatan logam kecil dan masih banyak lainnya. Pada proses ini memberikan keuntungan dari segi ekonomis dan teknis. Selain itu, proses mesin ini juga memiliki manufaktur yang tinggi. Sehingga, benda tuang yang terbuat dari non logam. Seperti magnesium, aluminium, tembaga, seng, timbal dan lain sebagainya. Dapat diproses dengan waktu yang relatif singkat. Sangat cocok untuk pembentukan benda kecil, sedang bahkan besar. Keuntungan yang diberikan oleh die casting adalah Waktu proses atau pengerjaan suatu produk relatif cepat dan sangat singkat,Mampu membentuk benda yang berdinding tipis,Dapat mengontrol ukuran produk yang dianggap berlebihan, Menghasilkan kualitas produk permukaan yang sangat baik,Memiliki kecepatan alir yang sangat yang ditimbulkan oleh die casting adalah Mesin jenis ini terkenal dengan harganya yang sangat mahal,Material yang ada banyak terbuang sia-sia,Dalam operasionalnya terkenal lebih tinggi dan sangat menguras kantong. Cara dan Prinsip Kerja Die CastingSecara singkat, proses die casting adalah material yang ada akan dipanaskan hingga melebur terlebih dahulu. Setelah cairannya telah lebur maka akan dilakukan sebuah injeksi dalam cetakan yang telah disediakan. Dalam mencetaknya, diberikan sebuah tekanan yang sangat tinggi. Dengan adanya tekanan tinggi, maka diperlukan sebuah alat untuk mengkompres dies yang mana umumnya terbuat dari tools steel. Pada proses ini, tak sembarangan dies yang dapat dan mampu untuk digunakan. Dalam proses kerjanya, dies menutup dan dikunci kemudian material akan diinjeksi. Setelah ditahan untuk beberapa saat, dies dibuka dan ejector menekan agar produk dapat keluar. Itulah pembahasan seputar die casting. Mulai dari pengertian dan penjelasan mesin ini, jenisnya, komponen yang ada, keuntungan dan kerugian yang diberikan serta prinsip atau cara kerjanya. Dengan adanya die casting ini, mampu mempermudah dan memberikan kelancaran bagi manusia yang ingin melakukan sebuah pencetakan logam. Caranya yang sangat mudah dan efisien, tak heran banyak orang yang memanfaatkan alat ini dalam dunia industri. High pressure die casting of aluminium alloys involves the control of metals travelling at high speed, being subjected to high pressures and high solidification Fundamentals of Aluminium Metallurgy, 2011Casting, Semi-Solid Forming and Hot Metal FormingG. Govender, ... Damm, in Comprehensive Materials Processing, CastingHPDC is a common process for forming nonferrous metal with low melting points. It is particularly suited for the high-volume production of comparatively complex near-net shape parts. Thixocasting via the HPDC route is currently being commercially used by V-Forge 92 and SAG 93 while the rheocasting route is being pursued by a number of research centers and to a lesser extent commercially. Casting processes with a significant solid fraction use the thixotropic behavior of the slurry to achieve laminar filling and hence produce high-integrity castings. The high-pressure die casting of SSM slurries can be achieved using cold chamber HPDC machines with horizontal injection and horizontal clamping, vertical injection with vertical clamping, and vertical injection with vertical recently, the slurry manufacturing process, in particular low solid fraction slurries, has been used in the in-sand castings as well 94. Slurries in this form can be used in a much wider range of casting full chapterURL processes for light Kridli, ... Boileau, in Materials, Design and Manufacturing for Lightweight Vehicles, 2010High-pressure die castingHigh-pressure die casting HPDC is a very commonly used process for creating structural components, especially in Mg. In this process, a metal die having a cavity with the negative geometry of the part is created; simple dies usually consist of two matching halves, while more complex dies can add sliding features that create holes and undercut areas. The die is mounted onto a machine capable of injecting molten metal at high velocities. The die cavity is closed, molten metal is poured into a shot sleeve, the sleeve opening is closed, and a ram moves forward to force the metal into the die in a very short time 10–100 ms, generating high levels of applied pressure. Following this, the ram pressure is maintained for a short time; often, active cooling occurs as internal water passages in the die are activated. Then, the pressure is released and the ram is withdrawn; the die opens and ejector pins push out part. The process cycle for the HPDC process is usually very rapid; for example, a current 110 lb HPDC V6 engine block has a process cycle time of approximately 90 seconds. The rapid speed of the HPDC yields a number of advantages. In terms of costs, HPDC creates castings with a high casting yield up to 95%, high to very high near net shape, high levels of surface finish, and high dimensional control; all of these factors minimize the amount of post-casting machining and finishing that must be depending on the size and geometry of the component, multiple cavity dies can be created; this allows for the production of multiple parts within each individual process cycle. Further, there are no sand/binder costs or issues associated with HPDC. Metallurgically, the rapid injection and cooling rates tend to yield a very refined microstructure with improved levels of mechanical properties. The use of internal cooling passages within the die means that the solidification of the molten metal and, hence, the microstructure can be controlled; this allows more optimized properties to be obtained in specific locations within the HPDC process also has several limitations. The most serious limitation is related to the need to have a die that opens and closes along a specific dimension the parting line’. This means that the desired component cannot be made with complex internal geometries while a major limitation for some components such as cylinder heads, this is less of an issue with structural components due to their simpler three-dimensional geometries. The up-front costs associated with HPDC are high; metal dies and tooling are required along with the hydraulically-actuated die-casting machine. Another issue is that this process is not easily scalable. The HPDC machines have a finite capacity for production; if the production requirements exceed this capacity, another machine must be purchased along with the dies and tooling. Metallurgically, the high injection velocities often entrap air in casting, allowing porosity to arise. Additionally, the rapid cooling rates can concentrate porosity and inclusions along the centerline of a casting. Both of these factors can reduce the mechanical properties of the casting. Also, the presence of the trapped air often prevents these castings from being heat-treated; thus, the maximum strength properties obtainable are often much lower in HPDC components compared with other permanent mold and sand-cast processes. Finally, the non-uniformity of properties tends to increase as the size and/or thickness of the HPDC component has been used to create a large number of magnesium automotive structural components. The grill opening reinforcement GOR in the current Ford F150 is a HPDC AM60 alloy structure. This structure consolidated eleven steel stampings into a single Mg casting while reducing the weight from 69 to 40 pounds. Instrument panels are further examples of high-volume > 4 million HPDC components cast from AM50/60 alloys. Examples include the Ford Expedition 14 steel stampings integrated into 1 Mg part with a 12 lb weight saving and the Cadillac CTS and STS 20 steel pieces integrated into 2 HPDC Mg parts.Read full chapterURL processes for light alloys* Kridli, ... Boileau, in Materials, Design and Manufacturing for Lightweight Vehicles Second Edition, High-pressure die castingHigh-pressure die casting HPDC is a very commonly used process for creating structural components, especially in Al and Mg. In this process, a metal die having a cavity with the negative geometry of the part is created; simple dies usually consist of two matching halves, while more complex dies can add sliding features that create holes and undercut areas. The die is mounted onto a machine capable of injecting molten metal at high velocities. The die cavity is closed, molten metal is poured into a shot sleeve, the sleeve opening is closed, and a ram moves forward to force the metal into the die in a very short time 10–100 ms, generating high levels of applied pressure. Following this, the ram pressure is maintained for a short time; often, active cooling occurs as internal water passages in the die are activated. Then, the pressure is released and the ram is withdrawn; the die opens and ejector pins push out part. The process cycle for the HPDC process is usually very rapid; for example, a current 110 lb. HPDC V6 engine block has a process cycle time of approximately 90 seconds. The rapid speed of the HPDC yields a number of advantages. In terms of costs, HPDC creates castings with a high casting yield up to 95%, high to very high near net shape, high levels of surface finish, and high dimensional control; all of these factors minimize the amount of postcasting machining and finishing that must be depending on the size and geometry of the component, multiple cavity dies can be created; this allows for the production of multiple parts within each individual process cycle. Further, there are no sand/binder costs or issues associated with HPDC. Metallurgically the rapid injection and cooling rates tend to yield a very refined microstructure with improved levels of mechanical properties. The use of internal cooling passages within the die means that the solidification of the molten metal and, hence, the microstructure can be controlled; this allows more optimized properties to be obtained in specific locations within the HPDC process also has several limitations. The most serious limitation is related to the need to have a die that opens and closes along a specific dimension “the parting line”. This means that the desired component cannot be made with complex internal geometries while a major limitation for some components such as cylinder heads, this is less of an issue with structural components due to their simpler three-dimensional geometries. The up-front costs associated with HPDC are high; metal dies and tooling are required along with the hydraulically actuated die-casting machine. Another issue is that this process is not easily scalable. The HPDC machines have a finite capacity for production; if the production requirements exceed this capacity, another machine must be purchased along with the dies and tooling. Metallurgically the high injection velocities often entrap air in casting, allowing porosity to arise. Additionally the rapid cooling rates can concentrate porosity and inclusions along the centerline of a casting. Both of these factors can reduce the mechanical properties of the casting. Also, the presence of the trapped air often prevents these castings from being heat-treated; thus the maximum strength properties obtainable are often much lower in HPDC components compared with other permanent mold and sand-cast processes. Finally the nonuniformity of properties tends to increase as the size and/or thickness of the HPDC component has been used to create a large number of magnesium automotive structural components. The GOR in the current Ford F150 is a HPDC AM60 alloy structure. This structure consolidated eleven steel stampings into a single Mg casting while reducing the weight from 69 to 40 pounds. Instrument panels are further examples of high-volume >4 million HPDC components cast from AM50/60 alloys. Examples include the Ford Expedition 14 steel stampings integrated into 1 Mg part with a 12 lb. weight saving, the 1996 GM Savanna/Express vans 67 parts integrated into 25 parts with a 12 lb. weight savings Fig. the 2013 Buick LaCrosse 10 lb. weight savings Fig. and the Cadillac CTS and STS 20 steel pieces integrated into 2 HPDC Mg parts. Die-cast Mg liftgate inner panels have been used on the 2010–19 Lincoln MKT, where a weight savings of 22 lbs. was obtained compared to a steel Fig. Die-cast Mg liftgate inner panels have been incorporated into the Chrysler Pacifica minivan as High-pressure die-cast Mg instrument panel beams A one-piece instrument panel beam for GMC Savana and Chevrolet express kg B current generation instrumental panel beam for Buick LaCrosse kg Luo, 2013.Figure High-pressure die-cast AM 60 Mg Lincoln MKT liftgate inner panel Luo, 2013.Read full chapterURL alloys for lightweight automotive structuresAlejandro Graf, in Materials, Design and Manufacturing for Lightweight Vehicles Second Edition, High pressure die castingHPDC is the most common process for the production of aluminum castings. The range of utilization extends from parts as light as 100 g or even less, to very complex engine blocks, powertrain, and suspension components. As sketched in Fig. molten metal is dosed into the “shot chamber” and pushed by a hydraulic ram into the die cavity at a controlled speed. The mold is filled rapidly, and a very high pressure up to 20 MPa is maintained during the solidification process. Because of this high-velocity filling, HPDC can produce shapes that are more complex than permanent mold casting with much thinner walls. The thin walls freeze extremely quickly when the metal comes in contact with the die walls, forming a skin responsible for high fatigue Schematic of the high pressure die casting method, indicating the sequence of problem with the rapid filling of the mold is the entrapment of air. Although this trapped gas might not be visible, as any porosity is closed due to the high pressure maintained during solidification, it renders the castings not heat treatable, difficult to weld and therefore not suitable for structural applications. Also, contrary to the low pressure method, the dies are not coated with a ceramic lining to maximize heat transfer and the formation of the skin. Therefore it is necessary to use high levels of Fe in HPDC alloys to avoid die soldering mold sticking. High levels of Fe promote the formation of undesirable Al–Fe–Si intermetallic phases that affect ductility, a requirement of structural full chapterURL Casting Permanent Mold Butler, in Encyclopedia of Materials Science and Technology, 20013 High-pressure Die CastingHigh-pressure die casting is a process in which molten metal is forced under pressure into a securely locked metal die cavity, where it is held by a powerful press until the metal solidifies. After solidification of the metal, the die is unlocked, opened, and the casting ejected. After removal of the casting, the die is closed and locked again for the next cycle. The injection of metal into the die cavity is completed in a fraction of a second. Often, while the molten metal is still held in the die, extremely high pressure is applied called intensification pressure. This high pressure compresses any gas entrapped in the metal and feeds additional metal into the cavity to compensate for the shrinkage of the metal as it types of systems are used for injecting the molten metal into the die. The hot chamber system is used with metals such as zinc, magnesium, and lead. The injection system of a hot chamber machine is immersed in the molten metal bath of the melting furnace. As the shot plunger moves, it forces metal through the nozzle and into the cold chamber system is used for metals that melt at high temperatures, such as aluminum, brass, and magnesium. Magnesium parts can be produced using both systems, though usually small parts are produced in hot chamber machines and large parts in cold chamber machines since hot chamber machines are limited in size. There are also two injection systems used in the cold chamber process, horizontal and vertical the cold chamber process, the molten metal is poured, by hand or by automatic means, into a port of the cold chamber sleeve. A hydraulically operated plunger advances through this steel sleeve, sealing off the port, and forcing the metal into the die at high speed and pressure. After solidification of the casting, the plunger is retracted, the die opened, the casting ejected, and the system is then ready for the next shot cycle. Higher pressure is used in this system than the hot chamber process. The production rate of a hot chamber machine is higher than that of a cold chamber machine because of the shorter time required during the pour operation. Typical zinc castings produced by the high-pressure die casting process are shown in Fig. 2. Typical zinc die addition to the conventional high-pressure die casting processes, several enhancements to the process have been developed in recent years. These enhancements include the use of vacuum systems to reduce entrapped gas, slower fill processes to eliminate turbulence during fill and permit the use of heat treatment to enhance mechanical properties of the castings, and the application of semisolid metal processing to produce pressure tight parts not normally able to be produced in high-pressure die casting. Each of these processes utilizes the fundamentals of high-pressure die casting, but with additional capabilities to produce high integrity parts. They also have developed unique names for the purpose of distinguishing themselves from the conventional processes of hot chamber and cold chamber die die casting utilizes a vacuum system on the die cavity to remove gas from the cavity prior to injection of the molten metal. The result is a high integrity part with very low levels of porosity and high mechanical properties. The process is used to produce critical components in light alloys, such as structural and safety components for motor vehicles. The process has higher costs than conventional die casting, but the parts produced justify the additional cost and they cannot be produced successfully in conventional die fill die casting is often called squeeze casting. This process is widely practiced throughout the world today for producing parts that must be heat treated to achieve the required mechanical properties. Many automotive components that have been converted from iron castings or weldments of castings and/or stampings are now produced in light alloys in the squeeze casting process. This process utilizes the advantages of the low-pressure die casting process, controlled filling, and directional solidification of the molten metal, as well as the advantages of high-pressure die casting, high-pressure solidification, and fast cycle times. Parts produced in the squeeze casting process include steering and suspension components, alloy wheels, steering knuckles, and control arms, and air conditioning parts, compressor scrolls. Parts are produced with both vertical and horizontal shot systems. A schematic diagram of a vertical shot horizontal squeeze casting machine is shown in Fig. 3. Vertical shot horizontal squeeze casting metal processing SSM is beginning to share some of the same markets as squeeze castings, as well as some of the smaller automotive components such as link arms, fuel rail parts, and drivetrain parts. In this process, the metal injected into the die is only about 50% liquid. The process offers distinct advantages in that the feed metal fills the cavity in a manner that is less turbulent than in conventional die casting. Furthermore, the casting is partially solidified at the onset of the process, thus the solidification “journey” is a much shorter one. The technical capabilities of the process include high integrity of the castings, high mechanical properties, the ability to cast thin walls, good dimensional accuracy, surface conditions similar to high-pressure die casting, and suitability for heat treatment and welding. Semisolid casting and SSM materials are covered in detail in Semisolid Processing, and Casting of Semisolid Metals Engineering ApplicationsThe advantages of high-pressure die casting include a higher production rate than with gravity or low-pressure casting. Also, the ability to produce castings with close dimensional control greatly reduces machining operations. Die castings have good surface finish, which is a prime requirement for plating, and much thinner wall thickness is possible reducing overall casting weight. Dies have a long life, reducing unit part costs, and more complex parts can be produced, thereby reducing the number of components required in an disadvantage of high-pressure die casting is that it is best suited to high volume parts. High tooling costs make short production runs uneconomical. Also, the internal porosity prevalent in conventional high-pressure die castings makes producing pressure tight parts difficult, often requiring the use of vacuum die casting, squeeze casting or SSM casting. There are a limited number of alloys suitable for die casting and this restricts the heat treatment or welding of the finished castings. Iron or steel alloys are normally not die castable. There are restrictions in die casting on the casting size and wall thickness which eliminate the possibility of die casting some parts, but this has been reduced with the development of the new high integrity processes of vacuum die casting, squeeze casting, and SSM casting. Die casting machine and maintenance costs are higher than for other casting full chapterURL pressure die casting of aluminium and its Murray, M. Murray, in Fundamentals of Aluminium Metallurgy, Aluminium alloys used in die Defining the alloysThere are two basic alloy groups used in high pressure die casting. These are based on Al-9Si and Al-12Si. These make up the majority of high pressure die casting alloys. There are many other alloys but these make up a much smaller percentage of the overall market. A range of alloys can be observed in many of the metal data sheets Aluminium Standards and Data, 1997.Typical alloys in each of the groups are•Al-9Si – LM24, A380, ADC8, CA313, AlSi8Cu3Fe•Al-12Si – LM6, A413, LM2, ADC12, AC3A, AlSi12High pressure die casting alloys tend to be secondary alloys, that is, they are made from recycled metal. Hence, it is common for the alloys to contain a number of additional elements that range from advantageous to tramp.•Silicon – aids fluidity and makes the alloy more castable.•Iron – reduces the rate of attack of the dies by the aluminium Makhlouf and Apelian, 2002.•Copper – increases the hardness of the casting. Excess can result in increased cracking.•Magnesium – increases combination of elements can result in the formation of large intermetallics called sludge Makhlouf et al., 2001; Fig. Hence, for die casting alloys, there is a Sludging Factor which is defined as Sludge factor with holding temperature Makhlouf et al., 2001.SludgeFactor=%Fe+2%Mn+3×%CrThe factor depends on the temperature that the metal is held. However, if the sludge factor goes above critical then either small intermetallics are formed in the casting, or large chunks are formed in the furnace. These sludge particles are very hard and can cause premature failure of any machining tools when the casting is Microstructure of typical alloysThe microstructures of typical high pressure die casting alloys are complex because•They are usually a secondary alloy and hence have a large number of elements that can form complex phases and intermetallics. They are not a simple binary alloy.•The solidification is not solely within the cavity. The metal often begins to solidify via dendrite formation in the shot sleeve. This is a relatively slow growth rate and hence large dendrites are formed with relatively large dendrite arm spacing. The metal then finishes this solidification within the cavity where the growth rate is much higher. Hence, small dendrites are formed in the cavity with relatively fine dendrite arm spacing.•The solidification does not proceed within a quiescent melt. During injection the metal is travelling at 20–50 m/s and hence concentration gradients typical of equilibrium solidification are not study of the microstructure of die casting alloys has been going on since at least 1929 Dix and Keller, 1929. An excellent review of data on the microstructure of Al-Si die casting alloys is given in the book by Makhlouf et al. 1998. An example of typical microstructures of an A380/LM24 alloy is presented in Fig. a and b Typical microstructure of an A380/LM24 alloy Makhlouf et al., 1998.As can be seen in Fig. the dendrite sizes are bimodal with larger dendrites that are formed in the shot sleeve and the smaller dendrites which are formed in the cavity. The ratio of the two depends on the percentage of solidification that occurs in the shot sleeve. In small machines around 250 tonnes locking force or less the amount of metal poured into the shot sleeve is small compared to the mass of the shot sleeve. The high surface area relative to the mass of the metal poured means that the aluminium will rapidly lose heat. With larger machines 1200 tonne locking force or more the amount of aluminium poured is a much larger ratio and hence the metal loses only a small amount of heat. The temperature of the shot sleeve and the metal poured into it are also important in determining the ratio of pre-solidified dendrites in the final casting. If the shot sleeve is relatively warm 300 °C according to Gershenzon et al., 1999 then virtually no solidification occurs in the shot sleeve. The effect of molten metal temperature is less important, as usually the metal is between 650 °C and 680 °C. If the molten aluminium is hotter than 700 °C then the amount of dissolved hydrogen becomes excessive, the level of magnesium in the melt tends to reduce and the growth rate of dross or oxides microstructure comprises silicon cuboids and eutectic silicon phases embedded in an a-aluminium matrix Suarez-Pena et al., 2007. Intermetallic needles of β-phase Al5FeSi, common in Al-Si alloys, are also present. Fe-bearing Chinese script with a composition similarto a-phaseAl15Fe,Mn3Si2 is also often present Makhloufetal., 1998. Acicular and polyhedral sludge particles of α-phase are nearly always morphology of the dendrites also depends on the processing parameters. Gunasegaram et al. 2007 produced tensile samples in a high pressure die casting machine using different gate velocities. They found that at higher gate velocities the dendrites decreased in size. Similarly, they noted that the porosity size and pore area fraction decreased with increasing gate velocity Fig. This combination led to an improvement in the yield strength Hall-Petch equation and the UTS maximum defect size. Pore fraction with changes in gate velocity Gunasegaram et al., 2007.Read full chapterURL of aluminium alloysS. Otarawanna, Dahle, in Fundamentals of Aluminium Metallurgy, Permanent mould castingLike HPDC and LPDC, permanent mould casting uses a metal die which can be reused. In permanent mould casting, molten metal is poured under gravity into a metal die so it is often referred to as gravity die casting. Like LPDC dies, the dies used for permanent mould casting are typically coated with a refractory material. Cores can be used and made from high alloy steels or resin bonded sands. Permanent mould casting is typically used for high-volume production of simple metal parts with uniform wall thickness. The minimum wall thickness that can be permanent mould cast is approximately 4 mm because of the limited ability of metal to run into thin sections. The process is used for the volume production ranging from 1000 to more than 100 000 per year. Common permanent mould parts include gears, automotive pistons and car wheels. The alloys commonly cast by permanent mould casting include 319 AlSi5Cu3, 413 AlSi12 and A356 AlSi7Mg.The casting operation ranges from manually operated hand-operated die sets to automatically operated carousel machines having several dies automatically operated and the melt is automatically poured. It typically takes around 4–10 minutes before the casting can be taken out from the die so the process is relatively slow. If higher production rates are required, multiple die sets have to be full chapterURL ProcessingJohn Campbell, in Complete Casting Handbook Second Edition, ImpregnationThe impregnation process is a sealing technique, designed to seal porosity and eliminate leakage problems in good casting processes do not need many instance HPDCs are highly prone to leakage problems because of their high content of bifilms and inflated bubble trails. Similarly, low pressure castings that have not had the benefit of the roll-over action following the filling of the mould are sometimes prone to an interconnected type of shrinkage porosity as a result of convection some casting operations use impregnation only to seal those castings that are shown to leak, others do not carry out an initial sorting test, but simply apply impregnation to all castings. Although, like heat treatment, impregnation is often carried out by specialist offsite operators at a price usually based on the weight of the casting, it is sometimes installed as an integral part of the foundry impregnation process involves the placing of the casting in a vessel from which the air is evacuated. The casting is then lowered into the sealing liquid. When fully immersed, air is re-introduced into the vessel to restore atmospheric pressure. In this way, the liquid is forced into the evacuated pores in the casting. The casting is then raised out of the liquid and is allowed to drain. Excess sealant is then washed off and the sealant is are two main curing processes based on two different sealing systems. These are 1 sodium silicate cured with the addition of a catalyst to the liquid and 2 a thermosetting resin hardened by a subsequent low temperature heat recent development is the streamlining of the process by the use of special sealants, allowing the process to be carried out in a single vessel with only a short treatment time Young, 2002.In a small percentage of cases, leakage of the casting is not cured by the first impregnation. Some casters and their buyers allow two or even three such attempts. Usually, if the casting still leaks after repeated attempts to seal it, it is finally full chapterURL manufactureJohn Campbell OBE FREng DEng PhD MMet MA, in Complete Casting Handbook, ImpregnationThe impregnation process is a sealing technique, designed to seal porosity and eliminate leakage problems in good casting processes do not need impregnation – however, many instance high-pressure die castings are highly prone to leakage problems because of their high content of bifilms and inflated bubble trails. Similarly, low-pressure castings that have not had the benefit of the roll-over action following the filling of the mold are sometimes prone to an interconnected type of shrinkage porosity as a result of convection some casting operations use impregnation only to seal those castings that are shown to leak, others do not carry out an initial sorting test, but simply apply impregnation to all castings. Although, like heat treatment, impregnation is often carried out by specialist off-site operators at a price usually based on the weight of the casting, it is sometimes installed as an integral part of the foundry impregnation process involves the placing of the casting in a vessel from which the air is evacuated. The casting is then lowered into the sealing liquid. When fully immersed, air is re-introduced into the vessel to restore atmospheric pressure. In this way the liquid is forced into the evacuated pores in the casting. The casting is then raised out of the liquid and is left to drain. Excess sealant is then washed off and the sealant is are two main curing processes based on two different sealing systems. These are i sodium silicate cured with the addition of a catalyst to the liquid; and ii a thermosetting resin hardened by a subsequent low-temperature heat recent development is the streamlining of the process by the use of special sealants, allowing the process to be carried out in a single vessel with only a short treatment time Young 2002.In a small percentage of cases leakage of the casting is not cured by the first impregnation. Some casters and their buyers allow two or even three such attempts. Usually, if the casting still leaks after repeated attempts to seal it, it is finally full chapterURL on the heat treatment of high pressure die Lumley, in Fundamentals of Aluminium Metallurgy, IntroductionAluminium alloys used for high pressure die casting are mostly those based on the alloying systems Al-Si-Mg and Al-Si-Cu and composition ranges of some of the more common alloys used worldwide are shown in Table Two important features of conventionally produced HPDCs are i the high turbulence experienced by the shot of molten metal as it is forced at high speed into a die and ii the very rapid rate at which it then solidifies. Because of this, castings often contain internal pores comprising entrapped gases, such as air, hydrogen or vapours, formed by the decomposition of organic lubricants. The gas content inside high pressure die cast parts varies between 10 and 50 cc/100 g normalised to ambient temperature and pressure Badini et al., 2002. Moreover, the gas volume is compressed by up to 1000 times during intensification under a metal pressure of 100 MPa during the casting process. Metal shrinkage during solidification and planar defects such as oxide skins or cold shuts may also result in porosity. The rapid rate of solidification also means that the microstructures developed within a high pressure die casting are usually inhomogeneous. The skin’ layer of metal is typically much finer and of higher integrity when compared to the internal structure of the casting. Examples of the skin and interior microstructures from a common A380 HPDC casting are shown in Fig. HPDC alloys from different world regions that are amenable to heat treatment*Alloy/wt% Al balSiFeCuMnMgNiZnPbSnTiOther totalCA313 Aus** US US US US US US US JIS JIS*** ISO eachAlSi9Cu3Fe DIN 226 Canada UK9– US DIN 239B CIS CIS + Sn are maximums unless presented as ranges.**May contain up to Cr.***ADC12Z contains up to 3% Optical microstructures of an A380 alloy as-cast a in the skin’ region of the casting and b the internal microstructure, showing the size and morphology of the solidified eutectic. Fe-bearing needles of the b Al5FeSi phase are arrowed in b Lumley et al., 2008a.While some level of porosity in die castings is normal Fig. the existenceofinternalporescontaininggasesunderpressuredoespresentasignificant disadvantage because components made from HPDC alloys that are age hardenable cannot be solution treated under the same conditions used for other casting alloys at 540 °C for eight hours. The gas-containing pores trapped within the microstructure expand resulting in unacceptable surface blistering. Swelling may also occur that changes the dimensions of the die cast parts, and can adversely affect mechanical properties. However, it has been shown recently that significant responses to age hardening are still possible if solution treatment temperatures and times are reduced Lumley et al., 2005, 2006, 2007a, 2007b. As a result, the mechanical properties of the common HPDC alloys can be substantially HPDC alloy in the as-cast condition showing porosity. The alloy was C380. Note that the microstructure is a mixture of shrinkage and gaseous porosity. The top left hand corner is towards the centre of the casting whereas the bottom right is towards the edge of the casting Lumley et al., 2005.Figure shows specimens of A360 alloy where an as-cast specimen a is compared with specimens that were heat treated using various solution treatment times and temperatures. Comparison of the as-cast specimen with the one that has been solution treated for 16 hours at 545 °C b reveals that the latter has suffered severe surface blistering and discolouration. Swelling has also occurred so that the specimen has become dimensionally unstable in both axial and longitudinal directions. When the solution treatment time was reduced to 15 minutes c note references to solution treatment time include that required to heat up, and the temperature was lowered, d–g, both blistering and dimensional change were significantly reduced. At temperatures of 515 °C and below f and g, blistering is Comparisons of the surfaces and internal microstructures of an A360 alloy solution treated under different conditions Lumley et al., 2007b.Included in Fig. are representative micrographs of sections prepared from the same components and the internal appearance of the castings corresponds to the blistering present on the sample surface. Based on Fig. it is clear there may be a thermal cycle within which the alloys can be at least partially solution treated. Subsequently, it was confirmed that alloy A360 retained a relatively high response to age hardening at 180 °C even though the solution treatment time was only 15 minutes and temperatures were progressively lowered from 540 °C to 485 °C Fig. In each case, the alloy aged rapidly at 180 °C and peak hardness was achieved after about two The hardening responses for A360 alloy aged at 180 ºC, following different solution treatment procedures Lumley et al., 2007a.Further investigations on the effect of solution treatment temperature were conducted on a different alloy having the composition other which corresponded to alloy C380 in Lumley et al., 2007a. In this case, substantial responses to age hardening were achieved over the range of 440 °C up to 490 °C, with solution treatment of 15 minutes immersion, followed by water quenching and ageing at 150 °C. The times to reach peak hardness for each solution treatment temperature were similar, although the actual peak hardness values and tensile properties decreased as the solution treatment temperature was reduced Fig. Lumley et al., 2007b. The effects of solution treatment temperature on tensile properties of HPDC alloy C380. Note that tensile elongations for all results shown in Fig. were between one per cent and two per cent. Five samples per condition were tested. Alloy specimens for tensile testing were flat specimens 70 mm long, 14 mm wide and 3 mm thick with a central gauge length of 30 mm and width of mm Lumley et al., 2007b.Figure also shows the influence of melt velocity at the gate on the tensile properties in the T6 treated HPDCs. At solution treatment temperatures of 470 °C and above, the samples produced at a melt velocity at the gate of 82 m/s have proof strength values approximately 25 MPa above those for which a lower melt velocity of 26 m/s was used. For tensile strengths, the difference was as high as 56 MPa. At lower solution treatment temperatures, melt velocity still had a significant effect on tensile strengths, but not on values of proof wider range of alloy compositions have since been examined to determine their respective responses to heat treatment Lumley et al., 2007, 2008a, 2009, 2009a, 2009b, 2009c. Of particular interest were the roles of the potent age-hardening elements Cu, Mg, Si and Zn. As discussed in other chapters, for heat-treated aluminium alloys containing these elements, strengthening precipitate phases such as θ′Al2Cu, S Al2CuMg β′Al3MgSi1 and Q′ Al5Cu2Mg8Si6 form within the aluminium grains. It is these precipitates that provide an impediment to the process of crystallographic slip, thereby increasing mechanical strength. Although up to three per cent Zn is permissible in some HPDC alloy variants, there is usually insufficient Mg present to form significant quantities of η′ precipitates, MgZn2.In the HPDC alloys containing high levels of Si, the contributions precipitation hardening may make to strengthening are additional to those arising from the presence of the Al-Si eutectic Fig. In this regard, an interesting comparison may be made between binary wrought Al-4Cu alloy and a HPDC composition containing a similar atomic percentage of Cu Table Within the aluminium grains, both alloys display a similar precipitate structure containing the θ′phase. For the binary Al-Cu alloy, the proof stress is 236 MPa, whereas for the more complex microstructure in the HPDC composition, the proof stress is 379 TEM micrographs of an A380 alloy aged to a T6 temper, showing the various features within the heat treated microstructure a shows grains within the solidified microstructure also showing silicon, and a or b intermetallic Fe-bearing particles, arrowed and b shows the precipitate structure present within the aluminium grains Lumley et al., 2008a.Table Comparison of properties developed from either the binary Al-Cu alloy or the more complex HPDC alloy, displaying a similar AlCu ratioProduct formAlloy wt%Alloy at%Atomic ratio Al Proof stress MPaTensile strength MPaElongation %Wrought T6Alloy 4 Lumley et al. 2008aAs shown with reference to Table and Fig. compositional differences in Al-Si-Cu die castings may cause large variations in mechanical properties after age hardening. In this example, nine different alloys were prepared in as-cast, as solution treated, T4 treated, or T6 treated conditions. Solution treatment was standardised at 490 °C for 15 minutes total immersion time in a circulating air furnace, followed by water quenching Lumley et al., 2005, 2006, 2007a, 2007b. Specimens for the T6 tempers were subsequently aged in oil at 150 °C for 24 hours and those for T4 tempers were aged at 25 °C for 14 days. As solution treated and quenched specimens were also prepared and the tensile properties were determined immediately following Compositions of nine alloys examinedAlloyFigure legendAlSiCuMgZnFeMnother1 base▲ Lumley et al. 2007 The mechanical properties of HPDC alloys based on Al-Si-Cu showing a elongation as a function of average proof strength and b tensile strength as a function of average proof strength for the as-cast, as-solution treated, T4 and T6 tempers Lumley et al., 2007c; see Table for legend. Five samples per condition were tested. Alloy specimens for tensile testing were cylindrical and had a total length of 100 mm with a central parallel gauge length 33 mm long and a diameter of ± mm.Typically, the as solution treated and quenched specimens displayed an approximate 30% decrease in proof stress compared to the as-cast condition, although elongation was increased. Ageing to the T4 temper raised the proof stress to about 30% above that for the as-cast condition with values ranging between 217 MPa and 275 MPa, and in most cases, there was a simultaneous increase in tensile elongation. Ageing to the T6 temper typically raised the proof stress by 100% or more. For Alloy 1, which contained lower Cu and Mg contents, the proof stress in the T6 temper was 352 MPa whereas for Alloy 5 which contained higher Cu and Mg content, the proof stress value was as high as 419 MPa. There was little additional benefit in adding more than Cu to the alloys, since the increases were more moderate compare Alloys 7 and 8 with Alloy 5. Likewise, there was no observed benefit by raising the Mg content above For example, Alloy 9 showed values of proof stress similar to those for Alloy 5, despite having elevated contents of both Mg and full chapterURL

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