PRESSURE DIE CASTING (ALUMINIUM)
[CODE NO.4048]
The pressure die casting processes consume almost twice as many tones of aluminium alloys as all other casting processes combined. These processes are especially suited to the production of large quantities of relatively small parts. Aluminium die cast parts may weigh up to around 5 kilograms.
Pressure die casting in aluminum alloy offers means for very rapid production of engineering and other related component even or intricate design. The technique has obvious advantages when a component is required in large quantities. However, for aeronautic space, defence and automotive applications, mechanical properties and durability are of primary importance It is, therefore, essential that the best features of design should be employed and optimum casting technique with minimum cost be adopted. Pressure die cast products are used in the form of components of various electrical electronic, mechanical instruments and appliances used in domestic as well as industrial field.
Types of Aluminum Alloys for Die Casting Applications
In this eBook, we shall focus on 7 different types of aluminum alloys that are die cast in most industrial setup.
These alloys include the following:
The K-alloy; this aluminum allow is known to possess the following key properties: resistance to corrosion improved cooling and zero post die casting operations.
Alloy 413; superior die casting properties and it possess good fluidity and guarantee better pressure tightness.
Alloy 383; it possesses the following key properties: dimension stability, ease of casting and good mechanical properties. It has superior corrosion resistance too.
Alloy B390; it is known for its superior wear resistance and high hardness. They are mainly used to die cast the internal combustion engine pistons.
The A360; it is mainly used to cast aluminum parts where pressure tightness and fluidity is a priority. It maintains corrosion resistance and strength even at elevated temperature.
Alloy A413; its properties are similar to that of the alloy A360. This alloy is mainly used to die cast hydraulic cylinder components.
Alloy A380; it has good thermal and mechanical properties. Their performance property is similar to most alloys listed above.
In summary, by the end of this section, you need to understand the basic properties of all the possible aluminum die casting alloys.
This is important when you need a specific aluminum alloy for a given application.
COST ESTIMATION
Plant Capacity 2 MT/Day
Land & Building (4000 sq.mt.) Rs. 4.64 Cr
Plant & Machinery Rs. 1.52 Cr
Working Capital for 2 Months Rs. 2.29 Cr
Total Capital Investment Rs. 8.84 Cr
Rate of Return 17%
Break Even Point 68%
INTRODUCTION
TYPES OF ALUMINUM ALLOYS FOR DIE CASTING APPLICATIONS
THESE ALLOYS INCLUDE THE FOLLOWING
PRESSURE DIE CASTING
ADVANTAGES OF PRESSURE DIE CASTING
DISADVANTAGES OF PRESSURE DIE CASTING
TYPES OF PRESSURE DIE CASTING
1. HIGH PRESSURE DIE CASTING
HIGH PRESSURE DIE CASTING PROCESS
TYPES OF HIGH PRESSURE DIE CASTING
HOT CHAMBER PROCESS
HOT CHAMBER PROCESS
COLD CHAMBER PROCESS
COLD CHAMBER PROCESS
ADVANTAGES
DISADVANTAGES
2. LOW PRESSURE DIE CASTING
LOW PRESSURE DIE CASTING PROCESS
ADVANTAGES
DISADVANTAGES
USES AND APPLICATION
APPLICATION OF PRESSURE DIE CASTING
B.I.S. SPECIFICATION
PROCESS FLOW CHART
PRESSURE DIE CASTING PROCESS
(1) HIGH-PRESSURE DIE-CASTING (HPDC)
PROCESS CYCLE
A. CLAMPING
B. INJECTION
C. COOLING
D. EJECTION
E. TRIMMING
(I) HOT CHAMBER TYPE
(II) COLD CHAMBER TYPE
HOT CHAMBER DIE-CASTING
FIG. 13.3 AIR BLOWN OR GOOSE NECK TYPE DIE CASTING SETUP
COLD CHAMBER DIE CASTING
ADVANTAGES
DISADVANTAGES
APPLICATIONS
MELTING PROCESS
MELT PREPARATION
THE PRIMARY PURPOSE OF MELT TREATMENT IS
(A) DEGASSING
DEGASSING PROCESS
MEASURING HYDROGEN CONCENTRATION
REDUCED PRESSURE TEST (STRAUBE-PFEIFFER)
QUANTITATIVE REDUCED PRESSURE TEST (SEVERN SCIENCE)
DENSITY MEASUREMENTS
INITIAL BUBBLE TEST (HYCON TEST)
RECIRCULATING GAS TEST (TELGAS, ALSCAN)
(B) FLUXING
X-RAY INSPECTION (REAL TIME RADIOSCOPIC INSPECTION)
QUALITY CONTROL
FINISHING PROCESS
PAINTING
TESTING
PRESSURE DIE CASTING MACHINE AND EQUIPMENTS
DIE CASTING MACHINES
ALL THESE AIM AT IMPROVING
CONSIDERATIONS WHEN BUYING DIE CASTING MACHINES
THE CRITICAL PARTS TO CONSIDER IN A MACHINE INCLUDE
THE FOLLOWING
THE PRESSURE DIE CASTING MACHINES
1. THE HOT CHAMBER PRESSURE DIE CASTING MACHINES;
2. THE COLD CHAMBER DIES CASTING MACHINES;
DIE CASTING MOLD
MARKET POSITION
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE
SERVICE ARE
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY
2. MARKETS
3. POWER AND FUEL SUPPLY
4. WATER SUPPLY
5. CLIMATE
6. TRANSPORTATION
7. WASTE DISPOSAL
8. LABOR
9. REGULATORY LAWS
10. TAXES
11. SITE CHARACTERISTICS
12. COMMUNITY FACTORS
13. VULNERABILITY TO WARTIME ATTACK
14. FLOOD AND FIRE CONTROL
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION
2. FIXED ASSETS
3. WORKING CAPITAL
4. BREAK-EVEN POINT
5. OTHER FIXED EXPENSES
6. MARGIN MONEY
7. TOTAL LOAD
8. LAND AREA/MAN POWER RATIO
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
PLANT LAYOUT
SUPPLIERS OF ALUMINIUM PRESSURE DI-CASTING
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF ALUMINIUM ALLOY INGOT
SUPPLIERS OF PICKLING ACIDS
SUPPLIERS OF PACKING MATERIALS
SUPPLIERS OF PAINT
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF PRESSURE DIE CASTING MACHINE
SUPPLIERS OF ALUMINIUM MELTING FURNACE
SUPPLIERS OF CNC LATHE MACHINE
SUPPLIERS OF PAINTING EQUIPMENTS
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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