Manufacturing – Casting methods - European Aluminium Association

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1.10.3 Examples of part produced for the automotive industry using semi-solid forming processes Examples of parts which have already been in production Master brake cylinder Wheels Fuel rails Version 2002 © European Aluminium Association (auto@eaa.be) 62
Examples of parts which are today in development Multilink suspension component Suspension part From left to right: steering knuckle, injection pump, space frame note Version 2002 © European Aluminium Association (auto@eaa.be) 63
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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 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: 1.10.2 Suitable alloys and their me
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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