Manufacturing – Casting methods - European Aluminium Association

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1.4.3 Process description – Core manufacturing See also: AAM – Applications – 1 Power train > Engine > Cylinder block This process applies entirely resin bonded sand cores. Specifically, silica sand is used in the polyurethane cold-box process. The core package comprises also the whole running and feeding system. The core packages are, to a large extent, assembled automatically. Production lines with a capacity of up to 160 core packages per hour are currently in operation. Extremely tight tolerances are achievable, so that e.g. grey iron liners can be placed into the core package with a position tolerance of +-0.3 mm. Usually, the core packages are stored in a buffer and then fed into the casting line. Inserted parts such as grey iron liners can be preheated by induction coils in their final position in the core package prior to mould filling. This guarantees reproducible and repeatable conditions concerning the contact between the grey iron liners and the aluminium cast alloy. Fully automatic core package assembly with robots Source: VAW Version 2002 © European Aluminium Association (auto@eaa.be) 22
Manual assembly of core packages for enging block castings Source: VAW Version 2002 © European Aluminium Association (auto@eaa.be) 23
Page 1 and 2: Manufacturing - Casting methods Tab
Page 3 and 4: 1 Casting methods 1.1 Overview of c
Page 5 and 6: 1.3 Green sand castings 1.3.1 Green
Page 7 and 8: 1.3.3 DISAmatic casting Automated g
Page 9 and 10: Influence of mold filling rate For
Page 11 and 12: Mould filling by an electro-magneti
Page 13 and 14: AGSC characteristics leading to cos
Page 15 and 16: Comparison: Distribution of Rm, con
Page 17 and 18: Shock Tower: Size 450 x 400 x 250 m
Page 19 and 20: Partly assembled core package for a
Page 21: Schematic diagram showing the econo
Page 25 and 26: 1.4.5 Process description - Roll-ov
Page 27 and 28: 1.4.6 Process description - Process
Page 29 and 30: 1.5 Gravity die casting 1.5.1 Chara
Page 31 and 32: 1.5.3 Rotacast ® Rotacast ® is a
Page 33 and 34: 1.6 Low pressure die casting 1.6.1
Page 35 and 36: 1.6.2 LPDC machine With active wate
Page 37 and 38: This 4000 ton (35MN) machine is clo
Page 39 and 40: 1.7.3 Typical automotive applicatio
Page 41 and 42: 1.7.4 Design considerations Low mag
Page 43 and 44: Al18Si (AA 391) Alloy Microstrucutu
Page 45 and 46: 1.8.2 VDC Process Vacuum Dies The p
Page 47 and 48: Shot control using defined paramete
Page 49 and 50: 6: Part is now cool and ready for f
Page 51 and 52: Shock tower Audi A8 Source: Alcoa A
Page 53 and 54: 1.8.5 Mechanical properties *The ta
Page 55 and 56: 1.9.2 UBE squeeze-casting machines
Page 57 and 58: Main processes used today in produc
Page 59 and 60: Metallurgical aspects of semi-solid
Page 61 and 62: 1.10.2 Suitable alloys and their me
Page 63 and 64: Examples of parts which are today i
Page 65 and 66: 1.10.5 Possible defects and ways to
Page 67 and 68: 1.11 Vacuum riserless castings 1.11
Page 69 and 70: 1.11.3 VRC / PRC - Processing of ch
Page 71 and 72: 1.11.5 VRC / PRC - Examples of part
Page 73 and 74:
1.12 Lost foam castings 1.12.1 Intr
Page 75 and 76:
Pattern molding unit Source: LWF/ZV
Page 77 and 78:
1.12.4 Pouring & finishing Simplifi
Page 79 and 80:
1.12.5 Advantages and disadvantages
Page 81 and 82:
1.13 Comparing casting techniques V
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