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| موضوع: كتاب Die Casting Metallurgy الثلاثاء 10 يناير 2023, 1:41 am | |
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أخواني في الله أحضرت لكم كتاب Die Casting Metallurgy Alan Kaye MSC, CEng, MIM Chief Metallurgist, Fry's Diecastmgs Ltd, London Arthur Street PhD, BSC Illustrations by Rudi Hercik Butterworths Monographs in Materials
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Chapter 1 Early developments in die casting Chapter 2 Die casting metals and alloys Chapter 3 The production of aluminium and its alloys Chapter 4 Aluminium alloy die castings Chapter 5 Aluminium as a substitute for cast iron Chapter 6 Silicon Chapter 7 Melting equipment for aluminium alloys Chapter 8 Inclusions and hard spots in aluminium alloys Chapter 9 Zinc and zinc alloys Chapter 10 The metallurgy of zinc alloys Chapter 11 Zinc alloy die castings Chapter 12 Melting processes for zinc alloys Chapter 13 Cryogenic trimming of zinc alloy die castings Chapter 14 Low melting point alloys Chapter 15 Magnesium and its alloys Chapter 16 Brass die casting Chapter 17 Ferrous die casting Chapter 18 Automatic metal transfer systems Chapter 19 Metal melting treatments Chapter 20 The measurement of metal losses Chapter 21 The metallurgy of die casting machines Chapter 22 Instrumentation Chapter 23 Lubrication developments Chapter 24 New developments in die casting Chapter 25 Pressure die casting dies Chapter 26 Thermal fatigue of die casting dies Chapter 27 Heat treatment of die steels Chapter 28 Surface treatments for steels Chapter 29 Developments in finishing processes d.Index Acetylene, die dressing, 223 Acurad, 35 Aerospace alloys, 37,135 Ageing of zinc alloys, 90 Air pressure machines, 5, 7,141 Air pressure metal transfer, 169 Alcoa process, 18 Alexander, W.O., 13 Alloy manufacture, 20, 93, 109 Alloy specifications, 20, 27, 29, 82, 83, 137, 153,304 Alloy steels, 252 Aluminium alloys, 5, 14, 20, 27, 29, 36, 44, 184,236,251,295 Aluminium alloys, melting, 50 Aluminium bronze, 161, 197, 260 Aluminium in brass, 152 Aluminium in zinc alloys, 82,86 Aluminium-magnesium alloys, 12, 21, 31, 36, 78,182 Aluminium ores, 17 Aluminium oxide, 71,189, 236, 295 Aluminium, production, 13, 14,17, 38,46 Aluminium, pure, 37, 39 Aluminium-silicon alloys, 10, 19, 23, 27, 35, 73,297 Aluminium-silicon-copper alloys, 28, 75 American Die Casting Institute, 285, 304' A-metal, 151 Ampcolloy, 197 Analysis, 20,209 Ancient castings, 2, 122 Anodizing of aluminium, 296 Anodizing of magnesium, 298 Anodizing of zinc, 96, 294 Antimony in brass, 152 Antimony in lead, 124 Anvilloy (see Matthey 4000) Argon, in metal transfer, 145 Arsenic in brass, 152, 156 Austenite, 274,278 Austenitizing, 271 Australian CSIRO, 105 Automation, 8, 64, 76, 100, 115, 126, 154, 168,223,224 Automobiles, use of die castings, 3, 44, 106, 137,161,236 Babbage,C.,2 Bainite, 276 Basin tilting furnaces, 58, 112 Batteries, 15, 122,126, 235, 238 Bauer, A.F., 31, 140 Bauxite, 17 Bayer, K.J., 17 BB Mod, 197 Bennett, F.G., 141, 232 Beryllium-copper, 197 Beryllium in magnesium alloys, 146 Biringuccio, V., 2 BNF Metals Technology Centre, 2, 143, 159, 201,204,262 BNF gateway system, 231 Bondal process, 295 Boronizing, 288 Brass die casting, 12,149,153, 204 Brass, melting, 157 Brass metal treatment, 184 Bright nickel plate, 292 Bronwite, 152 Bronze, 1 Buhler Brothers, 174,213, 272 Bulk melting furnaces, 53,109 Cadmium in zinc alloys, 89 Calypso alloy, 38 Carbon in steel, 274 Carbonitriding, 289 Carburizing, 289 Cascades (fountains), 256 Cast iron, 4 4 , 1 6 1 , 251 Castmaster machines, 128, 195 Cast to form, 251 Cast to size, 189, 25& Cathodic passivation, 293 Cementite, 274 305306 Index Ceramics, 169,171 Ceramic fibres, 68 Champion, W., 81 Channel induction furnaces, 60 Channelless inductor furnaces, 63 Chemical dip processes, 96, 139, 291, 295, 297 Chlorine, for degassing, 185 Chromating of magnesium, 297 Chromating of zinc, 96, 291 Chromium in aluminium alloys, 31, 37, 75 Chromium in steel, 252, 276, 287 Chromium in zinc alloys, 89,115 Chromium plating of zinc, 292 Chrysler, intake manifold, 45 Church, W., 2 CIPEC, 149 Clay, as source of aluminium, 17 Cobalt in steel, 158, 252, 253, 255 Codes of practice, 92 Cold chamber machines, 5, 141, 143, 195,237 Compocasting, 241, 244 Computers, 2,14,45, 201, 231, 247 Concentration of ores, 18, 80, 149 Continuous cooling curves, 277 Cooling passages, 103, 106, 256 Copper alloys (see also Brass), 15, 150,152 Copper die casting, 1, 161 Copper in aluminium alloys, 30 Copper in zinc alloys, 84, 88, 91,115 Copper ores, 15,149 Copper plating, 292 Copper production, 150 Cores, ceramic, 45, 164 Cores for ferrous die casting, 164 Cores, metal, 254,286,289 Core pulls, 199 Cores, expendable, 45 Corrosion, of aluminium, 30 Corrosion, of brass, 156 Corrosion, of magnesium, 139 Corrosion, of zinc, 96 Cost per unit property, 13 Craze cracking, 159, 221, 251, 262, 271 Creep resistance, 138 Cromodora, S.p.A., 138 Crucibles, 66, 76,109, 147 Cryogenic trimming, 95,117 Cryolite, 18,23 Cylinder blocks (see Engine blocks) DCRF vacttum system, 233 Degassing, 76, 184 DeLavaud process, 161 Design of dies, 102, 105, 231, 250 Design for die casting, 8,44,103 Design for die life, 273 Design for heat treatment, 284 Dezincification, 156 Diagnostic trolleys, 210 Diane de Gabies, 38 Die blocks, 230 Die Casting Research Foundation, 285 Diecasting Society, 8 Die bolsters, 247 Die cleaning, 157 Die cooling, 223, 256 Die filling time, 104, 140, 204, 213 Die inserts, 163, 247, 250, 263, 266, 271 Die life, 98,102,158, 244, 262, 272, 281 Die locking, 7, 203, 214 Die lubrication, 5, 126, 217, 222 Die temperature, 207, 216, 222 Die steels, for aluminium, 252, 271 Die steels, for brass, 158, 253 Die steels, for ferrous die casting, 161-163 Die steels, for zinc, 252 Dilatrometric curves, 277 Doehler, H.H., 3,194 Doehler-Jarvis, 31 Dow process, 139 Dowels (see Guide pillars) Dross, 115,180,190,193 Dual energy furnace, 56 Duplex chromium plate, 292 Eaton process, 161 Ejectors, 4,103, 247,286 Electric induction furnaces, 60, 138,158 Electric radiant furnaces, 68 Electric resistance furnaces, 67,112 Electroformed die inserts, 253 Electromagnetic metal transfer, 144,176 Electroplating, aluminium alloys, 295 Electroplating, magnesium alloys, 140, 298 Electroplating, zinc alloys, 291 Electrostatic lubrication, 226 EMB machines, 7,195 Energy, for metal production, 13, 18, 45, 51, 132,149 Engine blocks, 7, 31,35 Equilibrium diagrams, 24, 86,125, 136,151 Eros, 38 Eutectics, 10,24,87, 124 Expanded metal for batteries, 128 Extreme pressure lubricants, 218 Fatigue (see Thermal fatigue) Ferro-Di process, 162 Ferrous die casting, 161 Finishes, for aluminium alloys, 295 Finishes, for magnesium alloys, 297 Finishes, for zinc alloys, 291 Fire-resistant fluids, 198, 206 Fluidic metal transfer, 179 Fluidized beds, 281 Fluxes, in alloy production, 21 Fluxes, in metal melting, 76, 93,115, 144,181 Ford Motor Company, 45,135 Forging dies, 270 Franklin, H.H., 3 Freeze barrelling (see Cryogenic trimming) Freezing range, 11,150 Frommer, L., 7 Fuel oil, 50Index Fulmer Research Institute, 240 Fume collection, 20,186, 228 Furnaces (see Electric, Reverberatory, etc.) Furnace efficiency, 50, 65, 208 Fuso light alloys, 236 Gas, appliances, 96 Gas, fuel, 50 Gas nitriding, 286 General Motors, 35, 45 Goosenecks, 4, 105, 141 Grain structure, 10,15, 24, 87,135 Graphite lubricant, 218, 223 Gries machines, 100 Guide pillars, 230 Gutenberg, J., 2 Hair line cracking (see Craze cracking) Hall, C. and Herault, P., 17 Hanawalt,J.D., 141,144,145 Hardening of dies, 271, 278, 282 Hard spots, 71 Heat checking (see Craze cracking) Heat pipes, 257 Heat treatment of dies, 252, 264, 270, 274, 279 Hodler, vacuum system, 234 Holding furnaces, 66, 68, 111, 143 Horizontal machines, 5 Hot chamber machines for aluminium, 168 Hot chamber machines for magnesium, 140 Hot chamber for machines for zinc, 4, 14, 98, 112,196,237 Hot die steels, 252 Hot shortness, 12, 140 Hydraulic fluids, 198,206 Hydroelectric power, 18, 131 Hydrogen in metals, 184, 202 Hypereutectic alloys, 35 ILZRO alloys, 107 Immersed crucible furnace, 56, 65,112 Immersion tube furnaces, 100,113,143 Imperial smelting process, 81 Inclusions in castings, 71, 182, 186 Inclusions in die steels, 264 Indium in zinc alloys, 90 Injection pressure, 140, 213 Inlet manifolds, 44,133 Inserts in die castings, 21,93,100, 115, 121 Instrumentation, 8, 200 Intergranular corrosion, 4,84 Intermetallic compounds, 71,73 International Lead and Zinc Research Organization, 107,231, 236, 304 International Magnesium Association, 147, 304 Ion deposition, 285 Iron carbide (see Cementite) Iron in aluminium, 30 Iron in zinc alloys, 89 Italpresse machine, 195 Kite mark, 92 307 Lacquer finishes, 294 Ladles, 168,173 Laminations, for rotors, 39 Latent heat, 11,50 Launders, 110, 113 Lead-antimony alloys, 124,128 Lead alloy, die casting, 5,124 Lead, castings, 2,122 Lead in copper alloys, 151 Lead in zinc alloys, 5, 82, 89 Lead, production, 15, 122 Leidenfrost effect, 221, 225 Light Metal Founders' Association, 8, 201 Liquid nitriding, 286 Locking force, 203,214 Lost foam process, 45 Low pressure die casting, 44,171 Lubricants, for dies, 5,217 Lubricants, for machines, 228 Lubricants, for plungers, 227 Lubricants, storage, 229 Machining of castings, 28, 73, 77,139 Madison-Kipp machine, 4 Magnesium alloy die casting, 140 Magnesium alloys, 11,132,135, 137, 140 Magnesium alloys, melting, 183, 203 Magnesium-aluminium alloys, 135,137 Magnesium as substitute for aluminium, 133 Magnesium in aluminium alloys, 31 Magnesium in brass, 157 Magnesium in zinc alloys, 84, 88, 92 Magnesium ores, 131 Magnesium, production, 15, 131, 141 Mahle, 141 Manganese in aluminium alloys, 31, 239 Manganese in brass, 152 Manganese in magnesium alloys, 135-137 Manganese in zinc alloys, 90 Maraging steels, 255 Martensite,274 Massachusetts Institute of Technology, 240 Matthey 4000,259 Mazak, zinc alloy, 82 Mazak, gating program, 231 Measured slug melting, 164 Mechanical immersed pumps, 171 Mechanical transfer ladles, 172 Media for trimming, 120 Melting losses (see Metal losses) Melting-holding furnaces, 65 Mercury in zinc ores, 80 Mergenthaler, O., 2 Metal balance sheets, 190 Metal losses, 8,51,146,189 Metal pumps, 64,112 Metallizing, 288, 293 Micro crack chromium, 292 Microporous copper plate, 292 Mobile ladles, 64 Modification, 23 Molten metal deliveries, 51308 Molten metal, transport, 64 Motor cycles, 236 Molybdenum, 159,258 Molybdenum disulphide, 219, 230 Molybdenum in steel, 252 Muffle furnaces, 279 Nelmor process, 233 New Jersey Zinc Company, 84 Nickel in aluminium alloys, 31 Nickel in zinc alloys, 89, 115 Nickel plating, 292 Nimonics, 260 Nippon Light Metal Co., 236 Nitriding, 196,287 Nitrocarburizing, 287 Nitrogen, in cryogenic trimming, 118 Nitrogen, for degassing, 185 Nitrogen, metal transfer, 138,144 Noranda, zinc alloys, 108 Normagic metal transfer, 144 Norsk Hydro, 131,144 Novatome pump, 176 Oil hydraulics, 7,198 Oscillograph, 214 Outokumpa process, 149 Oxygen purging (see Pore-free casting) Pacz, A., 24 Paint finishes, 293,296 Paley commission, 14 Parashot,213 Paste-type lubricants, 218 Pearlite, 274 Pechiney alloys, 35, 38 Permanent mould casting, 24, 37,45, 107, 161 Pewter, 2,130 Phosphate ester, 198,206 Phosphorus in aluminium, 35 Pigment lubricants, 219 Pillars (see Guide pillars) Plasma nitriding, 286 Plastics, 13 Plastic coatings, 294 Plated scrap, 115 Plating (see Electroplating) Plungers, 201,205,211,227 Plunger tips, 196 Polak, J., 5 Pore-free casting, 37, 45, 235 Porosity, 37,128, 184, 204, 238 Preheating of dies, 277 Printing (see Typecasting) Pull bar machines, 3 Pumps, for aluminium, 171 Pumps for die casting machines, 7 Pumps, for zinc, 112 Pyral alloy, 37 Pyrometers (see Temperature control) Quality control, 92 Quenching of die steel, 278, 281 Index Radiant roof furnaces, 58 Recycling of metals, 20, 45,115,122,137 Reverberatory furnaces, 53, 181 Rheo casting, 179,241 Rohri, C , 5 Rotary furnaces, 181 Rotors, 39,287 Runner systems (see Design of dies) Sakui, S., 7 Salt baths, 280, 285 Schultz, J.,7 Science Research Council, 247 Scrap, melting, 93,115, 157 Scrap, recycling, 19, 45,181 S curves, 274 Sea, as source of metals, 15,132,150 Sealed quench furnace, 280 Secondary metals, 19, 20, 30,122, 149,181 Semi-solid metals, 239 Shot sleeves, 196, 227 Silicon in aluminium alloys, 21,23 Silicon in brass, 151 Silicon in zinc alloys, 90 Silicon nitride, 171 Silicon, production, 47 Silicones, 220 Sink and float process, 21 Sludge, aluminium, 73, 203 Sludge, zinc, 82 Sludging formulae, 75 Society of Die Casting Engineers, 75, 304 Soldering (galvanizing) of dies, 217 Soluble cores, 45 Solid solutions, 11,23,87 Solvent extraction process, 150 Spark erosion, 251, 277 Spectrographic analysis, 94, 209 Sprayable lubricants, 219, 223 Solvent lubricants, 219 Specifications, 20, 22, 81, 83, 137, 153, 304 Spray guns, 223 Stabilizing of zinc alloys, 91 Stainless steel, 166 Steel, heat treatment, 252, 262, 274 Steel, specifications, 252 Stihl, A., 141 Strauss, K., 181 Stress raisers, 270 Stress relieving, 272,276 Subnormal temperature, 95, 117 Sulfinuz process, 288 Sulphur dioxide, 80,139,144,146,183 Sulphur hexafluoride, 144,146,183 Surface treatment of steels, 285 Sursulf process, 288 Telemetal, 172,176 Temperature control, 77, 92, 112, 202, 208, 216 Tempering of steels, 269, 278 Thallium in zinc alloys, 90Index 309 Thermal fatigue, 262, 269 Thin-wall casting, 13,14, 103, 189, 207 Thixocasting, 179, 240, 242 Tie bars, 7,195 Time-temperature curves, 274 Tin alloys, 130 Tin in zinc alloys, 82, 89 Tin, production, 129 Titanium, 31 Titanium diboride, 171 Toggle links, 195 Tombasil, 152 Toyota process, 289 Toys and models, 102 Tribology, 229 Triulzi machines, 45 Tufftriding, 287 Tungsten, 159,259 Tungsten in steel, 252 Typecasting, 2, 123 TZM,157,163 Vacuum die casting, 232 Vacuum feed systems, 178 Vacuum heat treatment, 281 Van Wagner, 4 Vanadium in steels, 252, 289 Vertical machines, 5 Vickers, H., 7 Viton, 198 Volkswagen, 137 Washington monument, 38 Water-based lubricants, 220, 237 Water cooling of dies, 106,159 Water fittings, 152, 153 Water glycol, 198,206 Weight reduction, 44, 103, 132 Welding of dies, 264 Welding of maraging steel, 259 Wemco system, 21 Wheel balance weights, 125 Wheels, in aluminium, 37, 235, 238 Wheels, in magnesium 138 White spirit, 219 Wing, W., 2 ZA alloys, 108 Zamak, 82 Zinc Alloy Die Casters' Association, 8 Zinc alloys, 4, 81, 82, 86, 93,107, 231, 237, 252,291 Zinc alloys, melting, 183 Zinc Development Association, 304 Zinc in aluminium alloys, 31 Zinc in magnesium, 136 Zinc oxide, 157 Zinc, production, 14, 80 Zincate treatment, 295 Zirconium diboride, 171 Zirconium oxide, 173 Zincart process, 294
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