Browsing by Keyword "Die casting"
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Item Equipamiento y metodología para la determinación de la vida de materiales para moldes(2010) Abuin, A.; Galarraga, H.; Crespo, I.; Plaza, L. M.; Carnicer, P.; Vicario, I.; García, J. C.; SG; CIRMETAL; PROMETAL; Tecnalia Research & InnovationDies used in the non ferrous die casting process, have a limited service life due to the damage effect by surface cracking appearance. These cracks are mainly produced by thermal fatigue, which are promoted by a repeated heating and cooling process through working cycles. The existing demand to improve materials to extend the die's service life leads to the development of new equipments to test the material behaviour. INASMET-TECNALIA in collaboration with FEAF (Spanish Federation of the Foundry Associations), has developed a testing machine to evaluate the thermal fatigue behaviour of steels used to manufacture dies. This testing machine is able to test forty samples simultaneously, getting a remarkable advantage in regard to previous developed test equipment. The versatility of heating and cooling system makes possible to test all kind of materials in very different thermal fatigue conditions.Item Improvement of mechanical and corrosion behaviour in die casting magnesium alloys with the addition of grain refiners.(World Foundry Organization, 2014) Posada, Tomás; García, José Carlos; Vicario, Ibán; Crespo, Iñigo; Plaza, Luis María; Val, Diego; Borge, Gregorio; CIRMETAL; PROMETAL; Tecnalia Research & InnovationThis paper shows a work carried out to obtain better properties in magnesium alloys used on high pressure die casting process (predominantly AM60B and AZ91D). This study starts with the selection of grain refiner materials to be employed for these alloys. Simple elements such as Mn, Ti, C, Si⋯ and compound elements as ZnO, TiB2 were selected as promising grain refiners. Tensile strength and elongation were chosen as main mechanical properties to be tested employing a design of experiments and laboratory tests. The determination of the fading effect of the grain refiner on the magnesium melt bath is also discussed. This work shows also the results obtained after the addition of selected grain refiners on corrosion resistance, by a new corrosion evaluating method based on affected surface area instead of weight loosing. Finally the best refiner elements for the analysed alloys are assessed, determining their concentration and dissolving time to obtain the best mechanical and corrosion properties. Tensile strength increases up to 6% for AZ91D alloy and up to 12% for AM60B alloy, elongation is also increased and corrosion resistance is even improved in both alloys.Item Metamodels’ Development for High Pressure Die Casting of Aluminum Alloy(2021-10-31) Anglada, Eva; Boto, Fernando; García de Cortazar, Maider; Garmendia, Iñaki; CIRMETAL; Tecnalia Research & Innovation; FACTORYSimulation is a very useful tool in the design of the part and process conditions of high pressure die casting (HPDC), due to the intrinsic complexity of this manufacturing process. Usually, physics-based models solved by finite element or finite volume methods are used, but their main drawback is the long calculation time. In order to apply optimization strategies in the design process or to implement online predictive systems, faster models are required. One solution is the use of surrogate models, also called metamodels or grey-box models. The novelty of the work presented here lies in the development of several metamodels for the HPDC process. These metamodels are based on a gradient boosting regressor technique and derived from a physics-based finite element model. The results show that the developed metamodels are able to predict with high accuracy the secondary dendrite arm spacing (SDAS) of the cast parts and, with good accuracy, the misrun risk and the shrinkage level. Results obtained in the predictions of microporosity and macroporosity, eutectic percentage, and grain density were less accurate. The metamodels were very fast (less than 1 s); therefore, they can be used for optimization activities or be integrated into online prediction systems for the HPDC industry. The case study corresponds to several parts of aluminum cast alloys, used in the automotive industry, manufactured by high-pressure die casting in a multicavity mold.