This practical guide to product and process engineering of various aluminum castings emphasizes process and material characteristics; product-process-alloy integration; manufacturing aspects of aluminum casting; product design features; tooling design, feeding and gating design; product quality needs and specifications; and more.

"It's about time that a practicing engineer with casting and academic experience has written a book that provides answers to questions about squeeze casting and semi-solid molding/forming that many engineers and students of casting need answered." —Joseph C. Benedyk, PhD, Consultant and retired technical director, Alcoa High Integrity Die Casting Processes provides a comprehensive look at the concepts behind advanced die casting technologies, including vacuum die casting, squeeze casting, and several variants of semi-solid metalworking. Practical applications for these processes are illustrated in numerous case studies. This single-source reference tool presents the latest material in five sections: Basic concepts of die casting and molten metal flow High integrity die casting processes with case studies Product design considerations Controlling quality and avoiding defects Future advances under development Key coverage includes a survey of liquid metal flow, strategies to overcome the limitations of conventional die casting, and potential defects unique to high integrity die casting processes. Also featured are methods for minimizing porosity, reducing cost by design, practical applied statistical process control techniques, designing for manufacturability, and containment methods for potential processing defects. Several chapters present detailed real-world examples illustrating the broad range of applications possible using high integrity die casting processes. Included with this book is a CD-ROM containing PowerPoint(r) presentations for each chapter. These presentations can be used for training purposes in conjunction with numerous study questions designed to practically apply the content of the book to real-world situations. Selected PowerPoint(r) slides can be used to support engineering proposals, marketing presentations, or customer education seminars. High Integrity Die Casting Processes is a valuable reference for both component producers and component users alike. Process engineers, tool designers, manufacturing engineers, production managers, and machine operators will acquire a better understanding of these advanced die casting processes to optimize manufacturing and improve product quality. Component designers, product engineers, purchasing agents, buyers, supplier quality engineers, and project managers will gain insight into these processes and develop superior products by design.

A frequently misunderstood technology, die casting is considered the shortest route between raw material and near net shape. For many decades, high pressure die casting was viewed as an art based upon "seat of the pant" strategies. However, many of these crude reactions actually worked because the fundamental process is quite forgiving of eccentric

Die Casting Metallurgy focuses on developments in the metallurgy of die casting. Ore distribution, smelting methods, and energy requirements for the major non-ferrous metals that are die cast are considered. This text has 29 chapters; the first of which provides an overview of early developments in die casting. After explaining how metals and alloys are die cast, the book turns to the production of aluminum and its alloys, aluminum alloy die castings, and melting equipment for aluminum alloys. The chapters that follow explore the metallurgy of zinc and magnesium alloys; brass and ferrous die casting; automatic metal transfer systems; metal melting treatments; and the metallurgy of die casting machines. Developments in lubrication, die casting, and finishing processes are also considered. This book also describes pressure die casting dies, thermal fatigue of die casting dies, heat treatment of die steels, and surface treatment of steels. Some comparative alloy specifications are summarized and an attempt is made to correlate units of hardness, strength, and other properties. This book will be of interest to materials scientists and industrial materials engineers.

This volume contains the technical papers presented at the international symposium entitled “Processing and Fabrication of Advanced Materials VIII”, held in Singapore in 1999. This was the eighth in a series of symposia bringing together engineers and researchers from industry, academia and national laboratories, working on aspects related to the processing, fabrication and characterization of advanced materials, to present and discuss their latest findings. The proceedings also contain technical papers presented at two special symposia on biomaterials and magnesium technology.

This book, Casting Processes and Modelling of Metallic Materials, explores the various casting and modelling activities related to metallic alloy systems. The book provides results of research work conducted by experts from all over the globe to add to the research community in the era of the casting process and modelling. The book was edited by two experts in the field of materials science and modelling, Dr. Abdallah and Dr. Aldoumani, whom both have several publications in peer-reviewed journals, worldwide conferences, and scientific books. The book introduces the casting processes and then discusses the various issues and possible solutions. Over the past years, various models have been proposed and utilized to predict the performance of castings. Some of these models proved to be accurate whereas others failed to predict the casting performance. The strength of any predictive tool depends on the employment of physically meaningful parameters that replicate the real-life conditions. This has been illustrated in the current book with such predictive models and finite element (FE) modelling to illustrate the behaviour of castings in real-life conditions.