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2008 Issues Archive
27 February 2008
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Heat treatment makes tougher diecast parts
Australian researchers have developed a heat treatment process for high pressure aluminium diecasting that they claim can double mechanical strength of components, give higher fatigue resistance and improve energy absorption.
Roger Lumley of the Light Metals Flagship, one of nine “flagship” research groupings set up by CSIRO, the Australian central research organisation, said components treated with the new process show no surface blistering or dimensional changes from the as-cast part.
Fatigue resistance of heat-treated aluminium high pressure diecast (HPDC) components can be as high as for some wrought aluminium products, and the process may also substantially raise energy absorption during fracture, making such components potentially suitable for crash-sensitive structural duties. Lumley said: “We envisage this will make it possible to use HPDC components more widely in load-carrying structural and safety applications.”
In addition, treated parts exhibit thermal conductivity about 20% above their as-cast status, so for engine or transmission applications heat can be transferred or removed more efficiently.
The process can be used in existing production lines using conventional heat treatment plant such as continuous belt furnaces, fluidised beds or furnaces designed for rapid heat treatment.
Lumley said: “It’s an attractive option because the HPDC process is more cost-effective than other manufacturing methods in mass production, and the net increase in design strength post-treatment may allow castings to be made using up to 30% less metal.”
The researchers are also looking for partners for a new range of HPDC aluminium alloys that show extraordinarily rapid strengthening under heat treatment. The alloys can be heat treated to high strength in cycle times of only 30 minutes, where conventional aluminium casting alloys need up to 24 hours.
© PE Publishing, 27 February 2008
