Formation of a W-25%Cu nanocomposite during high pressure torsion

A coarse-grained W–25%Cu composite is subjected to high pressure torsion (HPT) at room temperature, 200 °C, and 400 °C, to different very large strains. The evolution of microstructure with increasing strain is investigated. It is shown that the HPT causes a strong refinement of W particles. No significant influence of the deformation temperature on the microstructure is revealed at small strains (64). A strong effect of the HPT temperature on the microstructure is found at larger strains (>64). It is demonstrated that the HPT can be successfully used to fabricate a W–25%Cu nanocomposite.

Thermal control of high pressure die casting using computational fluid dynamics

The quality of high pressure die castings is a function of many interdependent parameters. It has been observed that many defects detected in the HPDC castings can be tracked back to poor die temperature distribution in the critical areas. It has therefore been recommended that the development of a technique to directly control the critical features - making them less sensitive to thermal related parameters - be very beneficial to the HPDC industry. From the information obtained from thermal image (processing), computational fluid dynamics has been applied to design the layout of internal cooling system and assign the flow conditions such as flow rate and pressure of the cooling water. it is observed that CFD prediction provides an excellent insight into the thermal balance of the high pressure die casting.

Modelling of porosity defects in high pressure die casting with a neural network

High Pressure Die Casting (HPDC) is a complex process that results in casting defects if configured improperly. However, finding out the optimal configuration is a non-trivial task as eliminating one of the casting defects (for example, porosity) can result in occurrence of other casting defects. The industry generally tries to eliminate the defects by trial and error which is an expensive and error -prone process. This paper aims to improve current modelling and understanding of defects formation in HPDC machines. We have conducted conventional die casting tests with a neural network model of HPDC machine and compared the obtained results with the current understanding of formation of porosity. While most of our findings correspond well to established knowledge in the field, some of our findings are in conflict with the previous studies of die casting.

Cracking and blowout in an aluminium high-pressure die casting die

Die cracking and metal blowout have been identified as problems in production of the structural sump, a high pressure die cast aluminium part, at Ford's Geelong manufacturing plant. Visual inspection, thermography and strain measurements have been performed and results are consistent with the view that cracking and blowout are caused by excessive stresses and deflections, respectively, generated by bending of the sliding cores. Models are being developed for finite element simulation of the stresses and deflections in the die during production, with a view to eliminating the aforementioned problems.

Squeeze pin implementation in a high pressure die casting

This paper discusses the implementation of hydraulically operated squeeze pins to reduce porosity formation in cast aluminium bearing caps. Two complete sets are cast in an eight-cavity die with a 2000t cold chamber high pressure die casting machine. The initial die configuration used a sliding core assembly with stationary pins to core a through hole in a thick section of the front cam caps. This configuration resulted in high post machining scrap rates, primarily due to porosity associated with solidification shrinkage. Replacement of the sliding core assembly with a squeeze pin unit substantially reduced shrinkage porosity in the critical region, with consequent reductions in the scrap rate. The squeeze pins are actuated 1.5s after the piston reaches the high shot changeover position, but can be successfully engaged between I and 3.5 seconds after high shot changeover. Density measurements and visual inspection confirmed the substantial improvement in porosity levels in the critical region of the castings.

Integrated optimization system for high pressure die casting processes

High pressure die casting (HPDC) is a versatile process for producing engineered metal parts by forcing molten metal under high pressure into reusable steel dies. However there are a large number of attributes involved which contribute to the complexity of the process. A novel integrated approach is developed to optimize the high pressure die casting processes. The die temperature profiles will be studied with infrared thermograph technology and the internal cooling system will be optimized to provide even cooling to the components and the die. The heat stored in the die and the components is studied with image processing. Based on the geometrical profile of the components, cooling channels can be redesigned to improve the cooling efficiency while the cooling time is reduced. This will not only significantly improve the quality of the castings but also improve the productivity of the process.

Photodarkening of amorphous selenium under high pressure

The photodarkening phenomena of amorphous Se have been studied by the optical absorption coefficient, sound velocity and attenuation measurements. The light illumination at low temperatures induces the photodarkening, and the photodarkened state is completely recovered by annealing near 306 K corresponding to the glass transition temperature. The photodarkening is enhanced by application of pressure. The sound velocity decreases and the sound attenuation increases by the illumination at low temperature. These suggest that a structural disorder increases in the photodarkened state. Three stages are observed for the recovery process of the photodarkened specimen. The photodarkening and the recovery process are discussed on the basis of VAP (valence alternative pair) model.