Light Metal Alloys
MML 375
Gravity Die Casting & Squeeze Die Casting - Aluminium
Casting Process and their use in Automotive application
BT20MME008 Amey Mahajan
BT20MME010 Ashutosh Jaiswal
BT20MME011 Atharv Yadav
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CONTENTS:
1.
2.
3.
4.
Introduction
Gravity Die Casting
a. Advantage
b. Disadvantage
Squeeze casting
a. Types
b. Advantages
c. Disadvantages
d. Uses in automobile industry
Conclusion and reference
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INTRODUCTION
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USES OF
ALUMINIUM
ALLOYS
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https://www.aluminiumleader.com/economics/world_market/
INCREASING USE OF ALUMINIUM
IN AUTOMOBILE SINCE IT’S
INCEPTION
The first full aluminium body car, the Durkopp
sports car, was showcased at an international
exhibition in Berlin.
1901
A lot of companies later improved on this
basic aluminium engine design and used
it in various mass produced and racing
models, including in Formula-1 race cars.
Interest in aluminium parts surged after
the oil crisis
1899
RECENTLY
1970s
The first aluminium engine made its debut at
a race in Nice: it had been built by the
famous German inventor Karl Benz.
Obsessed with fuel economy, car
designers started replacing heavy steel
parts with lighter aluminium
substitutes to reduce the overall
weight of their vehicles.
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ALUMINIUM ALLOYS USED IN BASIC CAR
ALUMINIUM USED IN F1 CARS
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TYPES OF Al-ALLOYS USED
IN AUTOMOBILE FOR
DIFFERENT PURPOSES
https://uacj-automobile.com/types_and
_applications.htm
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LOW PRESSURE DIE
CASTING
Die casting
Die casting uses pressure to force molten aluminum into
a steel die. This type of casting is often used for mass
production of parts, which require a minimum amount of
finishing and machining
HIGH PRESSURE DIE
CASTING
Permanent mold casting
Sand casting
Strong castings are formed by pouring
aluminum into permanent steel
mold.Their rapid cooling rates generate a
more consistent microstructure, which can
improve the mechanical properties
significantly.
Sand casting is economical because
the sand can be reused multiple
times. It is also effective for creating
large moldings or those with detailed
designs.
ALUMINIUM CASTING
PROCESSES
Squeeze casting
Squeeze casting is the preferred metal matrix composite
manufacturing process for a wide range of commercial applications
because of its ability to mass produce, simpler process parameter
control, improvements in wettability of the reinforcements by the
liquid metal, better metallurgical quality of matrix alloys due to
solidification under pressure
https://www.reliance-foundry.com/blog/aluminum#:~:text=Aluminum%20castings%20are%20formed%20by,mold%20casting%2C%20and%20sand%20casting.
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Gravity Die Casting
In gravity die casting, a reusable mold made of metal,
typically steel or iron, is used to shape the molten metal. The
mold is preheated, and then molten metal is poured into the
mold under the force of gravity. The metal fills the cavity of
the mold, and then solidifies and cools, taking on the shape
of the mold cavity.
Gravity casting is a manufacturing process to make metal
parts in large quantities and high dimensional accuracy.
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Ref - https://www.italpressegauss.com/en-us/what-is-gravity-die-casting
Gravity Casting - Goal
In this process which can be fully automated, the molten metal is
poured directly from a ladle into a semi-permanent or permanent die.
The goal is to fill the die with minimum turbulence through one or more
channels to reduce oxidation and foaming. This minimises porosity and
inclusions, giving optimum metal characteristics and forms a dense
metal casting
The die is tilted to maintain uniform and non-turbulent flow of liquid
metal.
Ref - Gravity Die Casting Process - Advantages and Applications (learnmech.com)
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Ref https://www.giessereilexikon.com/en/foundry-lexicon/Encyclopedia/show/tilting-gravity-die-castin
g-process-4367/?cHash=5b6dcf89fdc430d3aa4789cd60799eac
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Gravity Casting - Process
● Preheating the mold: The mold is first preheated to a specific
temperature and sprayed with a lubricant. This helps to ensure
that the metal flows smoothly into the mold and that the metal
cools evenly.
● Pouring the molten metal: The molten metal is poured into the
ladle, then the Flow of the liquid metal into the mould is
controlled by tilting the die to avoid turbulent flow of the meta
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Gravity Die Casting Process - Advantages and Applications (learnmech.com)
Gravity Die Casting Overview, Process, Applications (caparo.co.in)
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Gravity Casting - Process
● Solidification: As the molten metal cools, it solidifies and takes on
the shape of the mold cavity. The cooling process must be
carefully controlled to ensure that the metal cools evenly and
solidifies completely.
● Ejection: Once the metal has solidified, the mold is opened, and
the part is ejected. The part may still be hot at this stage and will
need to be cooled further before it can be handled.
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Advantages
●
●
●
●
●
●
Produce dense, high quality castings with excellent mechanical
attributes like strength and stiffness.
Minimum investment required for small and medium volume
production
High dimensional accuracy and surface finish
Can be used to make complex parts making it suitable for
automotive industry.
Better Production Rates
Environmentally friendly
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Ref :- Gravity Die Casting Overview, Process, Applications (caparo.co.in)
Disadvantages
1. Limited production capacity: Gravity die casting is best suited
for mid- to high-volume production runs due to the time and
cost required to manufacture the molds. It may not be suitable
for low-volume or one-off production.
2. High initial cost of the mold
3. Not suitable for casting made of metals with a high melting
point
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Squeeze casting :
Squeeze casting is a single step process that combines the casting and
forging processes.the molten alloy is poured into the mold and solidify
under pressure. It is a modifications of diacasting that combines the
casting and forging processes. Between the plates of a hydraulic press the
molten alloy is solidified under high pressure, resulting in a pore free
components or products.
One of the main advantages of squeeze casting is that many varieties of
metal like both ferrous and nonferrous can be used in this process,
although magnesium, copper and aluminum are the most commonly used.
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Ref. Google
Fig. Squeeze Casting
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Traditional squeeze casting is divided into two types:
1.Direct Squeeze Casting
2.Indirect Squeeze casting
Direct Squeeze Casting
Direct squeeze casting is similar to the forging process. In this method, molten
metal is poured into the bottom half of the mold. The upper half is closed, causing
the entire mold to fill with the molten metal. With pressure applied over the whole
cavity, the solidification process begins. This process provides better heat transfer
to produce stable components.
Ref. Google wikipedia
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Indirect Squeeze Casting
Indirect squeeze casting is similar to high-pressure die casting. In this
method, the molten metal is injected into an indirect squeeze-casting
machine through a vertical or horizontal shot sleeve. From there, the
liquid metal is injected into the die chamber through a thicker gate and a
lower velocity than the velocity used in high-pressure die casting.
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The Advantages of Using Squeeze Casting
● The combination of forging and casting produces metal-based
components and products with better finishing and mechanical
properties.
● Less shrinkage due to high pressure.
● Higher density of components gives longer life.
● Low chances of porosity defects in casting products.
● Wide range of metals can be cast.
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Ref. [2]
Advantages contd…
● It is an economical process because most of the raw materials
that can be used here as well as scrap also.
● Good surface texture.
● No requirement of machining.
● Fine micro-structure with higher strength components.
The above advantages of squeeze casting make it suitable for
production of automobile components.
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Disadvantages of Squeeze Casting
● Since this process having many optimizing parameters so it needs
to be accurately controlled which slow the cycle time down and
may increase the process costs.
● There is no flexibility as tooling is dedicated to specific
components.
● Costs are very high due to complex toolings.
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Ref. [2]
Squeeze Casting in Automobile industry
Squeeze casting is an established shape casting process that is capable of
producing lightweight, high integrity automotive components that can be
used for structural applications.
In recent years the squeeze casting process has been used with various
aluminium alloys to produce near-net shape components requiring high
strength, ductility,pressure tightness or high wear resistance.
Ref.[1] S. CORBIT. and R. DASGUPTA, Squeeze cast automotive applications. SAE International
Congress and Exposition (1999)
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Automobile components by Squeeze Casting
Fig:(a) Bearing cup of Al (b) Knuckles
Ref. [1]
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General Applications of Squeeze Casting
● This process has been commercially succeeded in manufacturing
parts include an Al dome,ductile iron mortar shell and a steel bevel
gear.
● Al automotive wheels and pistons and gear blanks made of brass
and bronze.
● Other parts that have been squeeze cast include stainless steel
blades,super alloy discs.
● It is a promising solution for thick magnesium castings as compare
to HPDC.
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Applications in automobile industry:
1)Suspension links
●
●
●
●
●
Al alloy- A356.2
Yield strength- 241.7 MPa
Tensile strength- 305.8 MPa
Percent elongation - 10.27%
Hardness - 100 BHN
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Ref.[2]
Fig. Suspension LInks
Automobile applications contd…..
2)Front steering knuckles
● Yield strength- 244.5 MPa
● Tensile Strength- 302.8 MPa
● % elongation- 10.5%
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Ref.[2]
Fig. Front steering knuckle
Automobile applications contd…
3)Rear steering knuckles
● Alloy- Strontium modified
A356.2
● Yield strength- 241.3 MPa
● Tensile Strength- 303.4 MPa
● % elongation- 10%
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Ref.[2]
Fig. Rear steering knuckle
MODELLING OF AUTOMOBILE COMPONENTS
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Ref. [3]
CONCLUSION
➔ In conclusion both gravity and squeeze casting have their place
in the automobile industry and the choice between the two
method will depend on the specific requirement of the part in a
particular application.
➔ Gravity casting is well suited for large and complex part with
low pressure application while on other hand squeeze casting is
suitable for small to medium size part that require excellent
mechanical properties and thin wall sections.
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References:
[1] S. CORBIT. and R. DASGUPTA, Squeeze cast automotive applications
and squeeze cast aluminum alloy properties (199901-0343). SAE International Congress and Exposition (1999).
[2] R. DASGUPTA, C. BARNES, P. RADCLIFFE, and P. DODD, Squeeze casting of aluminum alloy
safety critical components for automotive applications. World Foundry Congress (2006).
[3] D. APELIAN and M. MAKHLOUF (eds.), High integrity aluminum die casting: alloys, processes,
& melt preparation. North American Die Cast Association (NADCA), Rosemount, Illinois (2004).
[4] Gravity Die Casting Process - Advantages and Applications (learnmech.com)
[5] Gravity Die Casting Overview, Process, Applications (caparo.co.in)
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THANK YOU!
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