Manufacturing – Casting methods - European Aluminium Association

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1.12.2 Pattern making & cluster assembly Pattern making. The initial material required for pattern making is expandable polystyrene (EPS). First step in the LFC-process is the pre-expansion of EPS beads. After maturing the beads are blown into a mould forming the pattern sections. The mould is then steamed to expand the beads further and tightly fill the cavity of the mould. Hot steam and expansion of the beads causes them to weld together. Cluster assembly. Complicated parts including undercuts and hidden cavities cannot be moulded in one working step, but are assembled from pattern segments into a final pattern. Joining techniques used are gluing, heated platen welding and plugging. In order to increase the efficiency of the total process several patterns are combined into a cluster and supplied with a common gate system, also made of EPS. Pre-expansion unit Source: LWF/ZVG Paderborn Version 2002 © European Aluminium Association (auto@eaa.be) 74
Pattern molding unit Source: LWF/ZVG Paderborn Pattern assembly Source: BMW AG Landshut Cluster with two cylinder heads Source: BMW AG Landshut Version 2002 © European Aluminium Association (auto@eaa.be) 75
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Manufacturing - Casting methods Tab
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1 Casting methods 1.1 Overview of c
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1.3 Green sand castings 1.3.1 Green
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1.3.3 DISAmatic casting Automated g
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Influence of mold filling rate For
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Mould filling by an electro-magneti
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AGSC characteristics leading to cos
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Comparison: Distribution of Rm, con
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Shock Tower: Size 450 x 400 x 250 m
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Partly assembled core package for a
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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 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: 1.12 Lost foam castings 1.12.1 Intr
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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