HIGH INTEGRITY DIE CASTING PROCESSES

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1 HIGH INTEGRITY DIE CASTING PROCESSES EDWARD J. VINARCIK JOHN WILEY & SONS, INC.

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3 HIGH INTEGRITY DIE CASTING PROCESSES

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5 HIGH INTEGRITY DIE CASTING PROCESSES EDWARD J. VINARCIK JOHN WILEY & SONS, INC.

6 This book is printed on acid-free paper. Copyright 2003 by John Wiley & Sons, New York. All rights reserved Published by John Wiley & Sons, Inc., Hoboken, New Jersey Published simultaneously in Canada No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, (978) , fax (978) , or on the web at Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, (201) , fax (201) , permcoordinator@wiley.com. Limit of Liability/ Disclaimer of Warranty: While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional where appropriate. Neither the publisher nor author shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages. For general information on our other products and services or for technical support, please contact our Customer Care Department within the United States at (800) , outside the United States at (317) or fax (317) Wiley also publishes its books in a variety of electronic formats. Some content that appears in print may not be available in electronic books. Library of Congress Cataloging-in-Publication Data Vinarcik, Edward J. High integrity die casting processes / Edward J. Vinarcik. p. cm. Includes index. ISBN Die-casting. I. Title. TS239.V dc Printed in the United States of America

7 To My Dearest Friend Ad Majorem Dei Gloriam

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9 CONTENTS Preface Figures and Tables xv xvii INTRODUCTION 1 1 Introduction to High Integrity Die Casting Processes Origins of High Pressure Die Casting Conventional High Pressure Die Casting Problems with Conventional Die Casting Strategies to Improve Die Casting Capabilities High Integrity Die Casting Processes 10 References 11 2 Molten Metal Flow in High Integrity Die Casting Processes Introduction Flow within a Fluid Flow at the Metal Fill Front Metal Flow in Vacuum Die Casting Metal Flow in Squeeze Casting Metal Flow in Semi-Solid Metalworking 22 vii

10 viii CONTENTS 2.7 Predicting Metal Flow in High Integrity Die Casting Processes 24 References 24 HIGH INTEGRITY DIE CASTING PROCESSES 27 3 Vacuum Die Casting Vacuum Die Casting Defined Managing Gases in the Die Managing Shrinkage in the Die Elements of Vacuum Die Casting Manufacturing Equipment Applying Vacuum Die Casting 40 References 42 Case Studies: Vacuum Die Casting 42 Introduction 42 B Post 43 Transmission Cover 44 Engine Component Mounting Bracket 45 Marine Engine Lower Mounting Bracket 46 Reference 49 4 Squeeze Casting Squeeze Casting Defined Managing Gases in the Die Managing Shrinkage in the Die Elements of Squeeze Casting Manufacturing Equipment Applying Squeeze Casting 57 References 58 Case Studies: Squeeze Casting 58

11 CONTENTS ix Introduction 58 Steering Knuckle 60 Valve Housing 61 Steering Column Housing 62 High Performance Engine Block 63 References 65 5 Semi-Solid Metalworking Semi-Solid Metalworking Defined Managing Gases in the Die Managing Shrinkage in the Die Microstructures in Semi-Solid Metalworking Semi-Solid Metalworking Equipment Billet-Type Indirect Semi-Solid Metalworking Thixomolding Direct Semi-Solid Metalworking Applying Semi-Solid Metalworking 82 References 83 Case Studies: Aluminum Semi-Solid Metalworking 84 Introduction 84 Fuel Rails 84 Control Arm 88 Swivel Bracket 89 Idler Housing 90 References 91 Case Studies: Magnesium Semi-Solid Metalworking 91 Introduction 91 Automotive Seat Frame 93 Wireless Telephone Face Plates 95

12 x CONTENTS Video Projector Case 96 Camera Housing 97 Laptop Computer Case 97 Power Hand Tool Housing 98 References Thermal Balancing and Powder Die Lubricant Processes Thermal Cycling Inherent to High Integrity Die Casting Processes Heat Checking and Soldering Containing the Effects of Heat Checking and Soldering Repercussion of Heat Checking and Soldering Containment Actions Thermal Management of High Integrity Die Casting Process Tooling Minimization of Thermal Cycling Effects with Powder Lubricants Applying Thermal Management Methods in Real World Applications 108 References 109 DESIGN CONSIDERATIONS FOR HIGH INTEGRITY DIE CASTINGS Design for Manufacturability of High Integrity Die Castings Introduction to Design for Manufacturability High Integrity Die Casting Design for Manufacturability Guidelines Automotive Fuel Rail Case Study Review 114

13 CONTENTS xi Fuel Rail Functional Requirements Case Study Analysis Method Review of the Z-1 Fuel Rail Design Review of the Z-2 Fuel Rail Design Further Design for Manufacturability Improvements Conclusions of the Case Study 122 References Component Integration Using High Integrity Die Casting Processes Introduction to Component Integration Hidden Costs in Every Component Analyzing Integration Potential Component Integration Using High Integrity Die Casting Processes Component Integration Case Study 129 References Value Added Simulations of High Integrity Die Casting Processes Introduction to Applied Computer Simulations Computer Simulations of High Integrity Die Casting Processes Applying Simulations Effectively Resources Planning Coupling Product and Process Simulations Commitment A Case for Sharing Simulation Data across Organizations 140 References 141

14 xii CONTENTS CONTROLLING QUALITY IN HIGH INTEGRITY DIE CASTING PROCESSES Applying Statistical Process Control to High Integrity Die Casting Processes Introduction to Statistical Process Control SPC Characteristic Types SPC Applied to Dynamic Process Characteristics Die Surface Temperature Case Study Applying SPC to High Integrity Die Casting Processes 154 References Defects in High Pressure Casting Processes Introduction Conventional Die Casting Defects Surface Defects Internal Defects Dimensional Defects Defects Occurring during Secondary Processing Defects Unique to Squeeze Casting and Semi-Solid Metalworking Contaminant Veins Phase Separation Predicting Defects 167 References 168 VISIONS OF THE FUTURE Future Developments in High Integrity Die Casting Continual Development New High Integrity Die Casting Process Variants Refinements of Magnesium Alloys 172

15 CONTENTS xiii 12.4 Emerging Alloys for Use with High Integrity Die Casting Processes Metal Matrix Composites for Use with High Integrity Die Casting Processes Reducing Tooling Lead Times Lost-Core Technologies Controlled Porosity Innovations Continue 178 References 178 STUDY QUESTIONS 181 Appendix A Common Nomenclature Related to High Integrity Die Casting Processes 201 Appendix B Recommended Reading 207 B.1 Books 207 B.2 Papers 208 B.3 Periodicals 209 Appendix C Material Properties of Aluminum 211 References 211 Appendix D Die Cast Magnesium Material Properties 215 Reference 218 Index 219

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