Improvement of impact resistance of aluminum and zinc based die cast parts by means of tool steel inserts

Download

index.pdf

Date

2011

Author

Kamberoğlu, Murat

Metadata

Show full item record

Item Usage Stats

171
views

51
downloads

High Pressure Die Casting (HPDC) is low-cost technique for the mass production of complex, non-ferrous parts. Despite its benefits such as dimensional accuracy, surface quality and high production rate; some mechanical drawbacks limit use of HPDC in production of critical parts especially under dynamical loads. This study aims to improve impact resistance and surface hardness of die cast parts by means of tool steel inserts. These inserts act as a barrier between the impactor and die casting alloy, in order to avoid surface deformation and reduce stress localization which leads crack formation. Except the impact surface, whole insert is embedded into the die casting alloy by placing them on specially machined die casting molds prior to the metal injection. The mentioned method was evaluated by mechanical test and micro-examinations which were applied on AISI D2 tool steel inserted A518.0, A413.2 and Zamak5 alloy samples. To see the effect of inserts on energy absorbance under single destructive loads, both monolithic (conventional) and inserted (produced by mentioned technique) samples were subjected to Charpy impact test. In order to observe its behavior under non-destructive, cyclic, low velocity impacts; a dedicated real rifle part was produced by this method and tested in the real service loads. Explicit Finite Elemental Analysis was also carried out to understand how the inserts increases the energy absorbance and protect the die cast body by simulating both destructive and non-destructive impact loads. In addition to these, micro-examinations were also conducted especially on insert-die casting alloy interface for chemical and physical interactions, defects and stability. In regards of experimental findings, mechanical feasibility of the method was achieved. It was proved that steel inserts improve energy absorbance, stress distribution and impact-surface hardness of die cast products.

Subject Keywords

Die-casting., Metallurgy.

URI

http://etd.lib.metu.edu.tr/upload/12613054/index.pdf
https://hdl.handle.net/11511/21063

Collections

Graduate School of Natural and Applied Sciences, Thesis

Suggestions

OpenMETU
Core

Surface energy and excess charge in (1x2)-reconstructed rutile TiO2(110) from DFT plus U calculations Unal, Hatice; METE, ERSEN; Ellialtıoğlu, Süleyman Şinasi (2011-09-09) Physically reasonable electronic structures of reconstructed rutile TiO2(110)-(1x2) surfaces were studied using density functional theory (DFT) supplemented with Hubbard U on-site Coulomb repulsion acting on the d electrons, the so called DFT + U approach. Two leading reconstruction models proposed by Onishi and Iwasawa [Surf. Sci. Lett. 313, 783 (1994)] and Park and coworkers [Phys. Rev. B 75, 245415 (2007)] were compared in terms of their thermodynamic stabilities.
Microstructural characterization of hypoeutectoid steels quenched from the Ae1 - Ae3 intercritical temperature range by magnetic barkhausen noise technique Boyacıoğlu, Beril; Gür, Cemil Hakan; Department of Metallurgical and Materials Engineering (2006) This thesis aims to examine the possibility of using Magnetic Barkhausen Noise technique in characterizing the ferritic-martensitic microstructure of hypoeutectoid steels quenched from the intercritical temperature range. For this purpose, rectangular specimens were prepared from SAE 1020, 1040 and 1060 steels. The specimens were heated at different temperatures within the intercritical temperature range and then quenched into water. Microstructures of the specimens were characterized by metallographic exam...
Characterization of dual phase steels by using magnetic barkhausen noise analysis Kaplan, Mücahit; Gür, Cemil Hakan; Department of Metallurgical and Materials Engineering (2006) The aim of this work is to nondestructively characterize the industrial dual phase (ferritic-martensitic) steels (DPS) by the Magnetic Barkhausen Noise (MBN) method. By quenching of AISI 8620 steel specimens having two different starting microstructures, from various intercritical annealing temperatures (ICAT) in the ferrite-austenite region, the microstructures consisting of different volume fractions of martensite and morphology have been obtained. The microstructures, strength properties and hardness val...
Effect of TiH2 particle size on foaming of aluminium Kubilay, Ceylan; Öztürk, Tayfur; Department of Metallurgical and Materials Engineering (2005) A study is carried out on the production of aluminum foams via powder processing. The study deals mainly with the effect of TiH2 particle size on the process of foaming. Mainly two TiH2 particle sizes were used; namely 27,5 ?m and 8,5 ?m. Foaming experiments were carried out at temperatures between 675oC ا 840oC. The viscosity of the system is adjusted by controlled addition of Al2O3. The study shows that choice of foaming agent size is influential in the foaming process. With the use of fine foaming agent,...
Investigation of the effect of orientation and heat treatment on the stress corrosion cracking susceptibility of 7050 aluminium alloy Çevik, Gül; Doruk, Mustafa; Department of Metallurgical and Materials Engineering (2004) In the present work, the effect of variation in specimen orientation and heat treatment on the Stress Corrosion Cracking (SCC) susceptibility of 7050 aluminum alloy was investigated in 3,5% NaCl solution and under freely corroding conditions. For this purpose, Constant Extension Rate Tests (CERT) was performed on precracked Compact Tension (CT) specimens and the Direct Current Potential Drop technique was applied to measure the crack lengths. In addition to crack length versus time curves, the relationship ...

Citation Formats

M. Kamberoğlu, “Improvement of impact resistance of aluminum and zinc based die cast parts by means of tool steel inserts,” M.S. - Master of Science, Middle East Technical University, 2011.