Manufacturing – Casting methods - European Aluminium Association

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Rotacaster Source: VAW AG Production line Rotacast ® : closed die with inserted cores before rotation into casting position. Version 2002 © European Aluminium Association (auto@eaa.be) 32
1.6 Low pressure die casting 1.6.1 LPDC description and product examples Cylinder head, Low pressure die casting Low pressure die casting is a well-known casting process, especially for aluminium wheels in passenger cars. The process is also used in the production of big V-engine blocks in hypereutectic aluminium alloys and in the casting of air-cooled cylinder heads for motor cycles. Mould filling is controlled by regulating the pressure in the casting furnace. The melt flows through the riser tube which is positioned under the melt surface of the furnace and fills the mould very smoothly with clean melt from the bottom up. After mould filling, solidification starts from the opposite end of the mould in the direction of the tube. By increasing the pressure in the casting furnace, good feeding is guaranteed. Cycle times are long due to the fact that the casting is connected to the big melt volume by the riser tube during solidification. Version 2002 © European Aluminium Association (auto@eaa.be) 33
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 and 22: Schematic diagram showing the econo
Page 23 and 24: Manual assembly of core packages fo
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: 1.5.3 Rotacast ® Rotacast ® is a
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

Manufacturing – Casting methods - European Aluminium Association

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