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A frequently misunderstood technology, die casting is considered the shortest route between raw material and near net shape. For many decades, high pressure die casting was viewed as an art based upon "seat of the pant" strategies. However, many of these crude reactions actually worked because the fundamental process is quite forgiving of eccentric
Die Casting Metallurgy by Alan Kaye,Arthur Street Pdf
Die Casting Metallurgy focuses on developments in the metallurgy of die casting. Ore distribution, smelting methods, and energy requirements for the major non-ferrous metals that are die cast are considered. This text has 29 chapters; the first of which provides an overview of early developments in die casting. After explaining how metals and alloys are die cast, the book turns to the production of aluminum and its alloys, aluminum alloy die castings, and melting equipment for aluminum alloys. The chapters that follow explore the metallurgy of zinc and magnesium alloys; brass and ferrous die casting; automatic metal transfer systems; metal melting treatments; and the metallurgy of die casting machines. Developments in lubrication, die casting, and finishing processes are also considered. This book also describes pressure die casting dies, thermal fatigue of die casting dies, heat treatment of die steels, and surface treatment of steels. Some comparative alloy specifications are summarized and an attempt is made to correlate units of hardness, strength, and other properties. This book will be of interest to materials scientists and industrial materials engineers.
PROCESS PARAMETERS OF AL ALLOY CASTINGS PRODUCED BY HIGH PRESSURE DIE CASTING by Dharmpal Deepak,Sulakshna Dwivedi,Nitin Dhawan Pdf
In the current study, an industrial product (electrical wire connector) have been casted in cold chamber die casting process using LM2 aluminium alloy to produce certain specimens to be assessed under the study for the determination of the responses ( mechanical properties such as impact strength, hardness and surface roughness). As cold chamber die casting is being popularly known for its efficient and accurate casting process which can process a broad range of castings with intricate shape easily, hence it requires a lot of study in controlling the process variables with optimum combination of process variables to produce defect free and sound casting. Therefore in the current study, the process variables such as pouring temperature (725oC, 750oC, 775oC), intensification pressure (170 kg/cm2, 180 kg/cm2, 190 kg/cm2), type of coating (oil+graphite coating, dycote+graphite coating and dycote coating) and type of cooling (air cooling, water cooling and oil cooling) have been varied at three levels and 9 different experiments have been designed using Taguchi array (L9 orthogonal array) to assess the effects of different combinations of process variables over the mechanical properties (impact strength, hardness and surface roughness). The study aims at selecting the optimum combination process variables on the basis of the responses resulted in the 9 experiments. The graphs for the responses (impact strength, hardness and surface roughness) against each process variables have been plotted and carefully observed to identify the significant process variable along with respective level of operation affecting the respective response. From the overall study, intensification pressure was concluded to be the most significant process variable with maximum contribution to the impact strength and surface finish. The micrograph images captured corresponding to the respective levels of intensification pressure (170 kg/cm2, 180 kg/cm2, 190 kg/cm2) revealed the presence of shrinkage porosity corresponding to lowest level of intensification pressure (170 kg/cm2) and with further increase in intensification pressure led to a decrease in the extent of presence of porosity. Dycote coating was considered as the most optimum coating with significant contribution to the hardness. Air cooling and oil cooling were equally significant process variables with equivalent contribution to the mechanical properties.
Comprehensive Materials Processing, Thirteen Volume Set provides students and professionals with a one-stop resource consolidating and enhancing the literature of the materials processing and manufacturing universe. It provides authoritative analysis of all processes, technologies, and techniques for converting industrial materials from a raw state into finished parts or products. Assisting scientists and engineers in the selection, design, and use of materials, whether in the lab or in industry, it matches the adaptive complexity of emergent materials and processing technologies. Extensive traditional article-level academic discussion of core theories and applications is supplemented by applied case studies and advanced multimedia features. Coverage encompasses the general categories of solidification, powder, deposition, and deformation processing, and includes discussion on plant and tool design, analysis and characterization of processing techniques, high-temperatures studies, and the influence of process scale on component characteristics and behavior. Authored and reviewed by world-class academic and industrial specialists in each subject field Practical tools such as integrated case studies, user-defined process schemata, and multimedia modeling and functionality Maximizes research efficiency by collating the most important and established information in one place with integrated applets linking to relevant outside sources