Analysis of Horizontal Squeeze Casting Process for Pipe Oil Part

Abstract

To achieve the laminar flow filling pattern in squeeze casting processes, many literatures [1-4] have reported that ideal velocity of liquid metal passing through the ingate should be between 0.1 – 0.5 m/sec. John Campbell [1] reported that liquid metal front speed velocity should be 0.4 m/sec in order to eliminate the gas porosity inside the casting. However, such slow speed requires the higher temperature of liquid metal and die. This results in not only the longer cycle time but also a coarser microstructure of the casting. In addition, the sample castings used in the literature are simple form castings which do not reflect the real castings used in daily life. In this study, the indirect squeeze casting processes is adopted to cast a motorcycle’s component originally produced by a high pressure die casting process. Based on shape and dimensions of the casting to get the real casting out for the mass production, melt’s speed must be higher than the level reported by the literatures (around 1 m/sec). As a result, a fully laminar flow may not be achievable. This is confirmed by the primary study of the process parameters and tooling design using the casting process simulation. However, by clinging on the two principles of the squeeze casting processes; (1) minimizing the amount of entrapped air by slowly fill the cavity and (2) reducing the amount of solidification shrinkage by pressurized solidification; the casting from two processes will be casted in order to compared the micro-structure and mechanical properties.