Analysis of vacuum melting, ultrasonic, and radiographic techniques for gas porosity evaluation in die castings

Journal ar
International Journal of Advanced Manufacturing Technology
  • Volumen: 67
  • Número: 1-4
  • Fecha: 01 julio 2013
  • Páginas: 745-757
  • ISSN: 02683768 14333015
  • Tipo de fuente: Revista
  • DOI: 10.1007/s00170-012-4519-z
  • Tipo de documento: Artículo
Parts manufactured using die-casting processes may have significant limitations, mainly due to the tendency for air to be trapped during die-cavity filling. The detection and accurate measurement of porosity due to trapped air are essential issues for improving the quality of manufactured parts. This paper focuses on a comparison of radiographic, ultrasonic inspection, and vacuum melting techniques for analyzing the porosity level due to trapped air in parts manufactured using die-casting processes. To this end, aluminum alloy parts manufactured in a horizontal cold chamber die-casting machine using different injection velocities and mold configurations are analyzed. For the radiographic and ultrasonic techniques, a methodology is established to determine the level of porosity in the part, while, for the vacuum melting technique, a test procedure is established and an expression is obtained to relate the quantity of gas trapped in the part with the pressure increments measured as the part is melted in a vacuum furnace. The advantages and limitations of these techniques to evaluate porosity levels in die-cast parts are discussed in detail. Finally, the possibilities of using these techniques to select operating conditions that reduce the amount of trapped air during the filling stage are analyzed. © 2012 Springer-Verlag London.

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