Energy Consumption of Die Casting Operations

doi:10.2172/822409

Title: Energy Consumption of Die Casting Operations

Full Record
Other Related Research

Abstract

Molten metal processing is inherently energy intensive and roughly 25% of the cost of die-cast products can be traced to some form of energy consumption [1]. The obvious major energy requirements are for melting and holding molten alloy in preparation for casting. The proper selection and maintenance of melting and holding equipment are clearly important factors in minimizing energy consumption in die-casting operations [2]. In addition to energy consumption, furnace selection also influences metal loss due to oxidation, metal quality, and maintenance requirements. Other important factors influencing energy consumption in a die-casting facility include geographic location, alloy(s) cast, starting form of alloy (solid or liquid), overall process flow, casting yield, scrap rate, cycle times, number of shifts per day, days of operation per month, type and size of die-casting form of alloy (solid or liquid), overall process flow, casting yield, scrap rate, cycle times, number of shifts per day, days of operation per month, type and size of die-casting machine, related equipment (robots, trim presses), and downstream processing (machining, plating, assembly, etc.). Each of these factors also may influence the casting quality and productivity of a die-casting enterprise. In a die-casting enterprise, decisions regarding these issues are made frequently andmore »« less

Authors:: Jerald Brevick; clark Mount-Campbell; Carroll Mobley

Publication Date:: Mon Mar 15 00:00:00 EST 2004

Research Org.:: The Ohio State University (US)

Sponsoring Org.:: (US)

OSTI Identifier:: 822409

Report Number(s):: DOE/ID/13843
TRN: US200413%%82

DOE Contract Number:: FC07-00ID13843

Resource Type:: Technical Report

Resource Relation:: Other Information: PBD: 15 Mar 2004

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE; ALLOYS; CASTING; ENERGY CONSUMPTION; FURNACES; MACHINING; MAINTENANCE; MELTING; OXIDATION; PLATING; PROCESSING; PRODUCTIVITY; ROBOTS; SCRAP

Citation Formats


                    Jerald Brevick, clark Mount-Campbell, and Carroll Mobley. Energy Consumption of Die Casting Operations.  United States: N. p., 2004. 
        Web.  doi:10.2172/822409.

Copy to clipboard


                    Jerald Brevick, clark Mount-Campbell, & Carroll Mobley. Energy Consumption of Die Casting Operations.  United States.  doi:10.2172/822409.

Copy to clipboard


                    Jerald Brevick, clark Mount-Campbell, and Carroll Mobley. Mon .  
        "Energy Consumption of Die Casting Operations".  United States.  
        doi:10.2172/822409.  https://www.osti.gov/servlets/purl/822409.

Copy to clipboard


                    
@article{osti_822409,

  title        = {Energy Consumption of Die Casting Operations},

  author       = {Jerald Brevick and clark Mount-Campbell and Carroll Mobley},

  abstractNote = {Molten metal processing is inherently energy intensive and roughly 25% of the cost of die-cast products can be traced to some form of energy consumption [1]. The obvious major energy requirements are for melting and holding molten alloy in preparation for casting. The proper selection and maintenance of melting and holding equipment are clearly important factors in minimizing energy consumption in die-casting operations [2]. In addition to energy consumption, furnace selection also influences metal loss due to oxidation, metal quality, and maintenance requirements. Other important factors influencing energy consumption in a die-casting facility include geographic location, alloy(s) cast, starting form of alloy (solid or liquid), overall process flow, casting yield, scrap rate, cycle times, number of shifts per day, days of operation per month, type and size of die-casting form of alloy (solid or liquid), overall process flow, casting yield, scrap rate, cycle times, number of shifts per day, days of operation per month, type and size of die-casting machine, related equipment (robots, trim presses), and downstream processing (machining, plating, assembly, etc.). Each of these factors also may influence the casting quality and productivity of a die-casting enterprise. In a die-casting enterprise, decisions regarding these issues are made frequently and are based on a large number of factors. Therefore, it is not surprising that energy consumption can vary significantly from one die-casting enterprise to the next, and within a single enterprise as function of time.},

  doi          = {10.2172/822409},

  journal      = {},

  number       = ,

  volume       = ,

  place        = {United States},

  year         = {Mon Mar 15 00:00:00 EST 2004},

  month        = {Mon Mar 15 00:00:00 EST 2004}

}

Copy to clipboard

Technical Report:

View Technical Report (0.45 MB)

DOI: 10.2172/822409

Save / Share:

Export Metadata

Save to My Library

Similar records in OSTI.GOV collections:

Energy Saving Melting and Revert Reduction Technology: Melting Efficiency in Die Casting Operations

Technical Report David Schwam

This project addressed multiple aspects of the aluminum melting and handling in die casting operations, with the objective of increasing the energy efficiency while improving the quality of the molten metal. The efficiency of melting has always played an important role in the profitability of aluminum die casting operations. Consequently, die casters need to make careful choices in selecting and operating melting equipment and procedures. The capital cost of new melting equipment with higher efficiency can sometimes be recovered relatively fast when it replaces old melting equipment with lower efficiency. Upgrades designed to improve energy efficiency of existing equipment maymore »« less
DOI: 10.2172/1057665

Full Text Available
Energy Saving Melting and Revert Reduction Technology (E-SMARRT): Development of Surface Engineered Coating Systems for Aluminum Pressure Die Casting Dies: Towards a 'Smart' Die Coating

Technical Report Dr. John J. Moore ; Dr. Jianliang Lin,

The main objective of this research program was to design and develop an optimal coating system that extends die life by minimizing premature die failure. In high-pressure aluminum die-casting, the die, core pins and inserts must withstand severe processing conditions. Many of the dies and tools in the industry are being coated to improve wear-resistance and decrease down-time for maintenance. However, thermal fatigue in metal itself can still be a major problem, especially since it often leads to catastrophic failure (i.e. die breakage) as opposed to a wear-based failure (parts begin to go out of tolerance). Tooling costs remain themore »« less
DOI: 10.2172/1050628

Full Text Available
Energy Saving Melting and Revert Reduction Technology: Improved Die Casting Process to Preserve the Life of the Inserts

Technical Report David Schwam, PI ; Xuejun Zhu, Sr. Research Associate

The goal of this project was to study the combined effects of die design, proper internal cooling and efficient die lubricants on die life. The project targeted improvements in die casting insert life by: Optomized Die Design for Reduced Surface Temperature: The life of die casting dies is significantly shorter when the die is exposed to elevated temperature for significant periods of time. Any die operated under conditions leading to surface temperature in excess of 1050oF undergoes structural changes that reduce its strength. Optimized die design can improve die life significantly. This improvement can be accomplished by means of coolingmore »« less
DOI: 10.2172/1057028

Full Text Available
Energy audit workbook for die casting plants

Technical Report Not Available

In a typical die-casting plant, it is possible to save as much as 15% of utility costs through common-sense actions without any appreciable capital expenditure. The workbook provides a do-it-yourself, fill-in-the-blanks approach to an energy-conservation program for die-casting plants that do not have full-time engineering personnel. Energy-conservation measures that demand no capital investment are: reduce the preheat time for molds and furnaces to the minimum required; preheat charge metal by storing on top of the furnaces; not over-fire; adjust the length of the mold preheater pilot flame to a minimum; lower the thermostats in the office area during the heatingmore »« less
Simple visualization techniques for die casting part and die design. Final report, July 1, 1995--September 30, 1997

Technical Report Miller, R.A. ; Lu, S.C. ; Rebello, A.B.

The objective of this work was to develop and test die casting design evaluation techniques based on the visualization of geometric data that is related to potential defects of problems. Specifically, thickness information is used to provide insight into potential thermal problems in the part and die. Distance from the gate and a special type of animation of the fill pattern is used to provide an assessment of gate, vent and overflow locations. Techniques have been developed to convert part design information in the form of STL files to a volume-based representation called a voxel model. The use of STLmore »« less
DOI: 10.2172/307965

Full Text Available

Similar Records