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Metals 2015, 5(1), 192-205; doi:10.3390/met5010192

Vacuum Die Casting Process and Simulation for Manufacturing 0.8 mm-Thick Aluminum Plate with Four Maze Shapes

1
Graduate School of Mechanical and Precision Engineering, Pusan National University, San 30 Chang Jun-dong, Geum Jung-Gu, Busan 609-735, Korea
2
School of Mechanical Engineering, Pusan National University, San 30 Chang Jun-dong, Geum Jung-Gu, Busan 609-735, Korea
*
Author to whom correspondence should be addressed.
Academic Editor: Anders E. W. Jarfors
Received: 3 December 2014 / Revised: 20 January 2015 / Accepted: 26 January 2015 / Published: 4 February 2015
(This article belongs to the Special Issue Casting Alloy Design and Modification)
View Full-Text   |   Download PDF [1901 KB, uploaded 4 February 2015]   |  

Abstract

Using vacuum die casting, 0.8 mm-thick plates in complicated shapes are manufactured with the highly castable aluminum alloy Silafont-36 (AlSi9MgMn). The sizes and shapes of the cavities, made of thin plates, feature four different mazes. To investigate formability and mechanical properties by shot condition, a total of six parameters (melt temperatures of 730 °C and 710 °C; plunger speeds of 3.0 m/s and 2.5 m/s; vacuum pressure of 250 mbar and no vacuum) are varied in experiments, and corresponding simulations are performed. Simulation results obtained through MAGMA software show similar tendencies to those of the experiments. When the melt pouring temperature is set to 730 °C rather than 710 °C, formability and mechanical properties are superior, and when the plunger speed is set to 3.0 m/s rather than to 2.5 m/s, a fine, even structure is obtained with better mechanical properties. The non-vacuumed sample is half unfilled. The tensile strength and elongation of the sample fabricated under a melt temperature of 730 °C, plunger speed of 3.0 m/s, and vacuum pressure of 250 mbar are 265 MPa and 8.5%, respectively. View Full-Text
Keywords: vacuum die-casting; thin plate; aluminum alloy; casting simulation; casting defects vacuum die-casting; thin plate; aluminum alloy; casting simulation; casting defects
This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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MDPI and ACS Style

Jin, C.K.; Jang, C.H.; Kang, C.G. Vacuum Die Casting Process and Simulation for Manufacturing 0.8 mm-Thick Aluminum Plate with Four Maze Shapes. Metals 2015, 5, 192-205.

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