Hand Book On Die Castings

This practical guide to product and process engineering of various aluminum castings emphasizes process and material characteristics; product-process-alloy integration; manufacturing aspects of aluminum casting; product design features; tooling design, feeding and gating design; product quality needs and specifications; product launches; and successful conversions of aluminum from steel and iron.

This historic book may have numerous typos and missing text. Purchasers can usually download a free scanned copy of the original book (without typos) from the publisher. Not indexed. Not illustrated. 1919 edition. Excerpt: ... 01-Pins A sufficient part of such inserts must always be left ex posed (extending from the casting) to permit the die t0 properly hold it in place. When the design does not permit this it is sometimes necessary to cut off the insert after the casting is made. The portion of the insert imbedded in the casting, commencing about Tlg" or more from the surface of the casting, should be knurled, flattened, grooved or squeezed to provide a better grip. Provision must always be made in the casting to firmly anchor the insert, having in mind the strength and characteristics of the particular die-cast metal used. ' i When studs are cast into a wall the opposite side of which is to be polished or finished, a better appearance will be presented if the base of_the stud is pointed to prevent its showing through on the surface, as suggested in the illustration Flat Springs Except in aluminum, springs may be inserted without draw' ing the temper. Springs are usually anchored by punching holes in them. In some cases eyelets are punched into the holes of the springs to give a better hold. Springs.003" to.005" thick should not be over %" wide as otherwise the metal in shrinking will "pucker" them. Tllbing Tubing may be used when the design calls for long thin walls which cannot be cast. It is sometimes used for its strength, or to afford a passage for corrosive liquids. It may be bent in any shape and used as an oil passage, following an irregular line through the casting. It is advisable to extend tubing into which cores cannot be fitted beyond the surface of the casting to prevent the tube from being filled with metal. Such tubes must also usually be braced with pins or cores in the die which are withdrawn when the casting...

"It's about time that a practicing engineer with casting and academic experience has written a book that provides answers to questions about squeeze casting and semi-solid molding/forming that many engineers and students of casting need answered." —Joseph C. Benedyk, PhD, Consultant and retired technical director, Alcoa High Integrity Die Casting Processes provides a comprehensive look at the concepts behind advanced die casting technologies, including vacuum die casting, squeeze casting, and several variants of semi-solid metalworking. Practical applications for these processes are illustrated in numerous case studies. This single-source reference tool presents the latest material in five sections: Basic concepts of die casting and molten metal flow High integrity die casting processes with case studies Product design considerations Controlling quality and avoiding defects Future advances under development Key coverage includes a survey of liquid metal flow, strategies to overcome the limitations of conventional die casting, and potential defects unique to high integrity die casting processes. Also featured are methods for minimizing porosity, reducing cost by design, practical applied statistical process control techniques, designing for manufacturability, and containment methods for potential processing defects. Several chapters present detailed real-world examples illustrating the broad range of applications possible using high integrity die casting processes. Included with this book is a CD-ROM containing PowerPoint(r) presentations for each chapter. These presentations can be used for training purposes in conjunction with numerous study questions designed to practically apply the content of the book to real-world situations. Selected PowerPoint(r) slides can be used to support engineering proposals, marketing presentations, or customer education seminars. High Integrity Die Casting Processes is a valuable reference for both component producers and component users alike. Process engineers, tool designers, manufacturing engineers, production managers, and machine operators will acquire a better understanding of these advanced die casting processes to optimize manufacturing and improve product quality. Component designers, product engineers, purchasing agents, buyers, supplier quality engineers, and project managers will gain insight into these processes and develop superior products by design.