Article
Nanoscience & Nanotechnology
Ewan Lordan, Yijie Zhang, Kun Dou, Alain Jacot, Chrysoula Tzileroglou, Paul Blake, Zhongyun Fan
Summary: This article reveals the probabilistic nature of high-pressure die casting, specifically addressing the scatter in the tensile ductility of die-cast Al8Si0.4Mn0.3Mg alloy. The study shows that reducing heat loss in the shot chamber can lead to a more homogeneous grain structure, resulting in a decrease in maximum pore size and an increase in minimum tensile ductility.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2021)
Review
Materials Science, Multidisciplinary
Ewan Lordan, Yijie Zhang, Kun Dou, Alain Jacot, Chrysoula Tzileroglou, Shihao Wang, Yun Wang, Jayesh Patel, Jaime Lazaro-Nebreda, Xiaorong Zhou, Teruo Hashimoto, Zhongyun Fan
Summary: This article provides an overview of the research conducted at the EPSRC Future LiME Hub on high-pressure die casting (HPDC) between 2015-2022. The study aimed to address the variability in tensile ductility of die-cast structures and develop innovative processing techniques. It was found that processing parameters and die design significantly influenced the microstructure and tensile ductility variability of die-cast products. Additionally, intensive melt shearing was found to induce grain refinement and enable novel heat treatment procedures.
Article
Nanoscience & Nanotechnology
Guodong Niu, Jeff Wang, Jinping Li, Jinwen Ye, Jian Mao
Summary: In this study, a chill layer with high supersaturation was observed on the surface of Al-7Si-0.5Mg die casting tensile samples. The chill layer has fine alpha-Al grains and its formation mechanism is attributed to the pre-solidified dendrites formed in the shot sleeve and the nonuniform velocity distribution of the melt. The chill layer with solute enrichment promotes the precipitation of tiny Mg2Si phase from the supersaturated alpha-Al grains, which improves the strength and ductility simultaneously.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2022)
Article
Engineering, Mechanical
Bartlomiej Dybowski, Andrzej Kielbus, Lukasz Poloczek
Summary: The work aims to investigate the influence of casting defects on the formation of blisters in AlSi10MnMg alloy structural components. Structural components must have high mechanical properties, especially high ductility, which requires a heat treatment process. However, exposure to high temperatures can cause blistering on the surface, which is unacceptable in the final product. The study found that blister formation primarily starts from casting defects, which create microstructural discontinuities.
ENGINEERING FAILURE ANALYSIS
(2023)
Article
Metallurgy & Metallurgical Engineering
J. P. Weiler
Summary: This paper summarizes the recent work on the measure of manufacturability in the magnesium diecasting industry, focusing on the popular Mg-Al system alloys such as AZ91, AM60, and AM50. It discusses the concept of castability and its relation to the development of innovative applications or improved properties in magnesium die-casting alloys. The paper also provides key findings on castability, how it is defined and evaluated, the influence of alloying elements on castability, and recommendations for future research.
JOURNAL OF MAGNESIUM AND ALLOYS
(2021)
Article
Nanoscience & Nanotechnology
Avik Samanta, Hrishikesh Das, Glenn J. Grant, Saumyadeep Jana
Summary: This study reports on the use of friction stir processing (FSP) to modify the microstructure and create a defect-free processing zone in HPDC A380 alloy. The study found that FSP can eliminate porosity, refine the microstructure, and improve tensile properties. The design of the tool and the pass strategy are also important for achieving defect-free, refined microstructure, and uniform tensile strength and ductility in HPDC Al alloys.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2022)
Article
Metallurgy & Metallurgical Engineering
Naoki Sahara, Reiya Ikeda, Shaohua Wu, Mitsuhiro Okayasu
Summary: This study experimentally examines the influence of sodium on the microstructural characteristics and mechanical properties of die-cast Al-Si-Cu-Mg (ADC12) alloy. The addition of 0.03% Na improves the mechanical properties by modifying the shape of Si eutectic particles. However, adding 0.04% Na or more leads to a decrease in mechanical properties due to the formation of shrinkage porosity. Furthermore, a T5 treating enhances the mechanical properties of Na-containing ADC12 alloy through the significant precipitation of fine CuAl2 and Mg2Si, while T6-treated samples show lower mechanical properties due to the formation of blister defects.
INTERNATIONAL JOURNAL OF METALCASTING
(2023)
Article
Nanoscience & Nanotechnology
Jianyue Zhang, Emre Cinkilic, Xuejun Huang, Gerry Gang Wang, Yuchao (Chad) Liu, J. P. Weiler, Alan A. Luo
Summary: The increased use of lightweight aluminum die castings in the automotive industry has prompted the development of new die casting alloys and their heat treatment processes. This paper presents the development of an integrated precipitation and strengthening framework based on an improved Kampmann-Wagner numerical (KWN) model to predict the hardness and yield strength of high pressure die casting (HPDC) Al-11Si-xMg alloys during T5 aging process. The study shows that the increased Mg content enhances the hardness and yield strength due to the formation of Mg2Si phase and higher precipitate density of needle-like Mg5Si6-beta'' phase.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2023)
Article
Engineering, Manufacturing
Avik Samanta, Robert J. Seffens, Hrishikesh Das, Anthony D. Guzman, Timothy J. Roosendaal, David Garcia, Miao Song, Glenn J. Grant, Saumyadeep Jana
Summary: This study employs friction stir processing to selectively modify the microstructure of high-pressure die-cast aluminum alloy A380. The technique effectively breaks down dendrites and Si particles, resulting in a homogenized distribution and refined microstructure. The process also eliminates porosity and improves the material's mechanical properties.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Materials Science, Multidisciplinary
Daliang Yu, Wen Yang, Wanqing Deng, Songzhu Zhu, Qingwei Dai, Dingfei Zhang
Summary: This study investigated the hot tearing mechanisms in Aluminum (Al) parts with complex structures using optical microscope, scanning electron microscope, energy dispersive spectrometer, and finite difference method. Shrinkage porosities and cracked brittle Fe-bearing phases were found in the casted specimens, with improper solidification sequence contributing to crack initiation in the engine. Numerical simulation supported the observation of microstructure, suggesting that solidification sequence promoted casting defects.
Article
Metallurgy & Metallurgical Engineering
Filip Nikolic, Ivan Stajduhar, Marko Canadija
Summary: This research focuses on using convolutional neural networks (CNNs) to detect porosity defects in aluminum alloys. Through training and testing with various aluminum alloy samples, the proposed custom CNN model demonstrates accurate prediction of porosity defects with a classification accuracy of 94%.
INTERNATIONAL JOURNAL OF METALCASTING
(2023)
Article
Materials Science, Multidisciplinary
Piotr Dudek, Joanna Bialon, Justyna Piwowonska, Wieslaw Walczak, Konrad Wrzala
Summary: In order to reduce costs in casting production due to the rising prices of energy and charge materials, tests were conducted on increasing the number of cavities with the required tightness of the casting in a pressure die. The tests were carried out in both High Pressure Die Casting process and Vacuum System. By optimizing the pressure die design through the selection of casting parameters and conducting CT tests and microstructure observations, it was found that the desired level of casting porosity can be achieved by using the Vacuum system and significantly reducing gas porosity in castings from 4% at atmospheric pressure to 1% at a vacuum of 300 mbar.
Article
Materials Science, Multidisciplinary
Guodong Niu, Langjie Zhu, Wangrui Ren, Yu Wang, Houwen Chen, Jianfeng Wang, Jian Mao
Summary: Ce atoms were added into Al-Cu-Mn-Zr alloys to investigate their effect on theta' precipitates. It was found that Ce atoms could enter the lattice of theta' precipitates and occupy the internal Cu atom sites. The interfacial stability of Cu-rich theta'/alpha-Al matrix with Ce addition was also evaluated, showing lower interface energy compared to theta' precipitates without Ce occupation. This means that Ce atoms can stabilize the metastable Cu-rich theta' precipitates and enhance their resistance to coarsening at elevated temperatures. Addition of 0.3Ce can improve the microstructural stability of theta' in the Al-7Cu-0.5Mn-0.2Zr alloy by enhancing the coherent interfacial stability of the Cu-rich theta'/alpha-Al interface.
MATERIALS CHARACTERIZATION
(2023)
Article
Automation & Control Systems
Mengwu Wu, Jinpeng Yang, Feng Huang, Lin Hua, Shoumei Xiong
Summary: A practical bimetallic casting consisting of aluminum matrix and cast iron inserts was manufactured using the high-pressure die casting process. Different surface treatment methods were adopted to improve the bonding quality of the bimetallic castings. The results showed that a flawless and continuously metallurgical bonding interface can be achieved by using the zinc rack plating treatment on the surface of cast iron inserts.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Eva Anglada, Fernando Boto, Maider Garcia de Cortazar, Inaki Garmendia
Summary: The study focuses on the development of metamodels for high-pressure die casting process, based on gradient boosting regressor technique, which can predict secondary dendrite arm spacing and some defects with high accuracy and speed.
Article
Computer Science, Artificial Intelligence
Marco A. de Oliveira, Osmar Possamai, Luiz V. O. Dalla Valentina, Carlos A. Flesch
EXPERT SYSTEMS WITH APPLICATIONS
(2012)
Article
Computer Science, Artificial Intelligence
Marco Aurelio de Oliveira, Osmar Possamai, Luiz V. O. Dalla Valentina, Carlos Alberto Flesch
EXPERT SYSTEMS WITH APPLICATIONS
(2013)
Article
Green & Sustainable Science & Technology
Carime dos Santos Souza, Maria Lucia Pereira Antunes, Luiz Veriano Oliveira Dalla Valentina, Elidiane Cipriano Rangel, Nilson Cristino da Cruz
JOURNAL OF CLEANER PRODUCTION
(2019)
Article
Management
Tamie Takeda Yokoyama, Satie Ledoux Takeda-Berger, Marco Aurelio de Oliveira, Andre Hideto Futami, Luiz Veriano Oliveira Dalla Valentina, Enzo Morosini Frazzon
Summary: This paper proposes a framework that combines Bayesian networks with lean office to guide the implementation of lean office through value stream mapping, with a more reliable prioritization of lead time reduction. A case study conducted in a product development department validates the feasibility and effectiveness of the proposed framework. The paper contributes to increased knowledge by exploring the combination of Bayesian networks and lean office in theory, and provides an easy-to-use and understandable tool for managers and professionals in different industries to reduce lead time in practice.
OPERATIONS MANAGEMENT RESEARCH
(2023)
Article
Management
Marco Aurelio de Oliveira, Luiz Veriano Oliveira Dalla Valentina, Osmar Possamai
INTERNATIONAL JOURNAL OF PRODUCTIVITY AND PERFORMANCE MANAGEMENT
(2012)
Article
Automation & Control Systems
J. M. Crichigno Filho, C. R. Teixeira, L. V. O. D. Valentina
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2007)
