Commercial, aluminum die-cast alloys are subject to long-term stresses leading to viscoelastic material responses resulting in inefficient engine operation and failure. Constant load creep tests were conducted on aluminum die-casting alloys: B-390, eutectic Al-Si and a 17% Si-Al alloys. Rupture occurred in the primary creep regime, with the eutectic alloy having the longest times to failure. Pr...

Non-destructive testing using ultrasonic measurement is used to ensure the quality of the die-casting products. The quality of a casting depends on the presence of discontinuities such as porosity and on the final metallurgical structure. Discontinuities occurring in the sub-surface of the cast structure mostly have irregular surfaces which scatter the ultrasound waves and make ultrasonic testi...

Abstract: This study presents the research results of effect that refining process has on porosity and mechanical properties of high pressure die castings made of AlSi12S alloy. The operation of refining was carried out in a melting furnace with the use of an FDU Mini Degasser. Mechanical properties (UTS, YS, Elongation, Brinell Hardness) were assessed on samples taken from high pressure die ca...

This research study proposes an innovative analysis for controlling the defects in aluminium die casting industry. In this analysis, casting process of a two-stroke engine oil pump body is concentrated. The component selected has often rejected due to blow hole defects. Six Sigma, the zero defect approach, is used in this study. Define measure, analyse, improve and control (DMAIC) problem solvi...

A new and innovative approach is presented to integrate sensors in materials and set up “smart materials”. Semi-finished parts are functionalized by printed sensors and printed interconnects. These functionalized parts are then further processed to components. This is a new and simple approach to integrate sensors in a material. Two examples of printed sensors and the process of integration are...