The Ostergren model is simple in form and widely used in engineering practice, also serving as the modeling basis of both the damage differentiation and crack propagation models. However, the shortcomings of the Ostergren model are that the modeling...
While zinc die-casting alloy Zamak is widely used in vehicles and machines, its solidified state has yet to be thoroughly investigated experimentally or mathematically modeled. The material behavior is characterized by temperature and rate sensitivit...
The fracture performance and damage prediction of die-cast materials are critical to guarantee the safe application of die-cast structural components in lightweight vehicles. Monotonic loading experiments were conducted on different shapes of die-cas...
The northeastern part of the cyclonic Rim Current, which encircles the entire basin of the Black Sea, is named as the Northeast Caucasian Current. It periodically approaches the coast, triggering the formation of topographic generated eddies, includi...
The Northeast Caucasian Current (NCC) is the northeastern part of the cyclonic Rim Current (RC) in the Black Sea. As it sometimes approaches the narrow shelf very closely, topographically generated cyclonic eddies (TGEs) can be triggered. These eddie...
This manuscript presents an advanced modeling methodology developed to accurately simulate the temperature field evolution in the die and wheel in an industrial low-pressure die casting (LPDC) machine employed in the production of A356 automotive whe...
The availability of tools for predicting quality in high pressure die casting is a challenging issue since a large amount of defects is detected in components with a consequent worsening of the mechanical behavior. In this paper, a tool for predictin...
Simulation is a very useful tool in the design of the part and process conditions of high-pressure die casting (HPDC), due to the intrinsic complexity of this manufacturing process. Usually, physics-based models solved by finite element or finite vol...
Nine-link type double-toggle mold/die clamping mechanisms are widely used in modern injection molding machines and die casting machines in order to provide sufficient mold/die clamping force for counteracting the pressure occurred inside molds/dies....
This study aims to bridge the critical knowledge gap in understanding the dynamic microstructural evolution during high-solid-fraction semi-solid rheo-die casting process, including slurry preparation (0.1–0.3 K/s) and rheo-die casting (10&ndas...
In the cold chamber high pressure die casting process (CC-HPDC) for light alloys, the piston lubricants play a key role in protecting the piston tip from wearing and ensure adequate seal with the shot sleeve. However, during the production process, t...
Most of the published research work related to the fatigue life of porous, high-pressure, die-cast structures is limited to a consideration of individual isolated pores. The focus of this article is on calculating the fatigue life of high-pressure, d...
The structural optimization of manufacturable casting parts is still a challenging and time-consuming task. Today, topology optimization is followed by a manual reconstruction of the design proposal and a process assurance simulation to endorse the d...
The well-established Total Cost of Ownership (TCO) concept has been applied to several durable goods industries, including machinery. However, none of the existing TCO models explicitly focus on such highly energy-intensive equipment as metal melting...
It is currently a challenge to accurately predict the deformation and fracture behavior of metal parts in automobile crashes. Many studies have shown that the deformation and fracture behavior of materials are significantly affected by the stress sta...
High-pressure die casting (HPDC) has been extensively used to manufacture aluminum alloy heat dissipation components in the fields of vehicles, electronics, and communication. With the increasing demand for HPDC heat dissipation components, the therm...
Tracking the microstructural evolution during high-pressure die casting of Al-Si alloys is challenging due to the rapid solidification, varying thermal conditions, and severe turbulence. The process involves a transition from slower cooling in the sh...
Mechanical and thermal sequences impact largely on thermo-mechanical fatigue of dies in a die casting operations. Innovative techniques to optimize the thermo-mechanical conditions of samples are major focus of researchers. This study investigates th...
This paper investigates the determination of secondary dendrite arm spacing (SDAS) using convolutional neural networks (CNNs). The aim was to build a Deep Learning (DL) model for SDAS prediction that has industrially acceptable prediction accuracy. T...
This study presents the development and process integration of an alternative demoulding system for high-pressure die casting. The system is aimed at the removal of large structural castings, which are becoming increasingly popular in the industry un...
This paper uses computational fluid dynamics (CFD), in the form of the OpenFOAM software package, to investigate the forces on the salt core in high-pressure die casting (HPDC) when being exposed to the impact of the inflowing melt in the die filling...
Taking an aluminum alloy gearbox of an automobile as an example, according to its structural characteristics, the parting surface was determined, and the initial gating system was designed by using 3D modeling software UG. Based on Magmasoft software...
PIG (Pin-Injection-Gate) die-casting and hot stamping was developed for fabrication of small-sized and thin-walled aluminum alloy parts from the recycled feedstock. The pure aluminum and aluminum alloy granules were utilized as a feedstock model of r...
At present, the qualified rate of large thin-walled magnesium alloy castings is low. In this study, the effects of mold structure and process parameters were investigated to improve the production qualification rate of castings. The filling process o...
This study investigates the melt-flow behavior of the AlSi9Cu3 alloy during high-pressure die casting using a combined experimental and numerical approach. A transparent die and a high-speed camera were used to capture the transient motion of the mel...
A large number of material and process parameters affect both the part quality and the process performance in pressure die-casting (PDC) processes. The complex relations between most of these variables make PDC process optimisation a difficult issue...
With the increasing demand for high-performance leisure boat propellers, this study explores the development of high-strength aluminum alloy propellers using the low-pressure die-casting (LPDC) process. In Part I of the study, we identified the optim...
Quality assurance in aluminum die casting is critical, as internal defects—such as porosity—can compromise structural integrity and significantly reduce component service life. In the cost-sensitive manufacturing environment of Germany, e...
The resulting quality of castings indicates the correlation of the design of the mold inlet system and the setting of technological parameters of casting. In this study, the influence of design solutions of the inlet system in a pressure mold on the...
Although numerical simulation accuracy makes progress rapidly, it is in an insufficient phase because of complicated phenomena of the filling process and difficulty of experimental verification in high pressure die casting (HPDC), especially in thin-...
The detection of hidden defects in materials using X-ray images is still a challenge. Often, a lot of defects are not directly visible in visual inspection. In this work, a data-driven feature marking model is introduced to perform semantic pixel ann...
RT-DETR (Real-Time DEtection TRansformer) has recently emerged as a promising model for object detection in images, yet its performance on small objects remains limited, particularly in terms of robustness. While various approaches have been explored...
Detection and characterization of hidden defects, impurities, and damages in homogeneous materials like aluminum die casting materials, as well as composite materials like Fiber–Metal Laminates (FML), is still a challenge. This work discusses m...
In this study, laser oscillation welding was utilized to offer an effective solution for the joint welding of heat-treatment-free die-cast aluminum alloys, which expands the practical applications of automotive structural parts and heat sinks for ele...
The quality and productivity of die castings are directly influenced by the injection system performance of the die-casting machine, making advanced performance monitoring of paramount importance. However, with the present technology, it is impossibl...
Automotive manufacturers are changing their product models faster due to the customization of users’ demands. In response, suppliers must react by improving the flexibility of their means of production and making the changeover process more eff...
As a key component of the die-casting machine, the flow linearity of the high-pressure, large-flow proportional throttle valve is a critical factor affecting injection accuracy at low openings. However, under existing main valve structures, flow line...
This work proposes a data-driven design framework for high-pressure die-cast (HPDC) aluminum alloys that integrates robust data refinement, machine learning (ML) modeling, explainability, and inverse design. A total of 1237 tensile-test records from...
An integrated precipitation and strengthening model, incorporating the effect of precipitate morphology on precipitation kinetics and yield strength, is developed based on a modified Kampmann–Wagner numerical (KWN) framework with a precipitate...
ADC12 aluminum alloy has been widely used in the aerospace, ship, and automotive fields because of its high specific strength, excellent die-casting performance, and wear resistance. Adhesion wear is the main wear mechanism of high-speed milling ADC1...
This study investigates the influence of pre-corrosion damage on the fatigue behavior of AlSi10MgMn high-pressure die-cast specimens, using the statistical distribution of corrosion depths. The analysis is conducted on two different surface condition...
This paper presents a hybrid methodology to analyze the commercial measures of changing stator windings and adjusting air gap length to upgrade efficiency of typical three-phase direct-on-line induction motors with die-cast copper rotor (DCR). The ca...
The investment casting method supported with 3D-printing technology, allows the production of unit castings or prototypes with properties most similar to those of final products. Due to the complexity of the process, it is very important to control t...
Investment casting is a widely utilized casting technique that offers superior dimensional accuracy and surface quality. In this method, the wax patterns are employed in the layer-by-layer formation of a shell mold. As is customary, the patterns were...
Macrosegregation is commonly seen and has been extensively studied in large ingots in a variety of alloy systems. In comparison, this defect is rarely investigated in small aluminum shape castings. To address this shortcoming, a numerical model was d...
In this work, a plant trial was conducted on an industrial low pressure die casting (LPDC) manufacturing process for the production of aluminum alloy wheels. Various types of data have been acquired, including extensive measurements of temperature at...
During high-pressure die casting, a significant amount of heat is dissipated via the liquid-cooled channels in the die. The jet cooler, also known as the die insert or bubbler, is one of the most commonly used cooling methods. Nowadays, foundries cas...
High-pressure die casting (HPDC) can produce precise geometries in a highly productive manner. In this paper, the failure location and cycles were identified by analyzing the fatigue behavior of the die subjected to repeated thermal stress. An energy...
Aluminum-silicon-magnesium alloys are commonly used in the automotive industry to produce structural components. Among usual quality controls of produced castings, microstructure characterization and determination of mechanical properties are the mos...
The low-pressure die casting (LPDC) process was experimentally and numerically studied to produce AlSi7Mg0.3 components such as steering knuckles. Steering knuckles are important safety components in the context of a vehicle’s suspension system...
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