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The specific product chosen was a side door inner panel for a mid-size car. The purpose of this project was to develop a process and product which would utilize magnesium die casting and result in energy savings when compared to the baseline steel product. Furthermore, through reducing the pouring velocity, the air gas entrapments and partial shrinkages were eliminated effectively.ĭevelopment of Integrated Die Casting Process for Large Thin-Wall Magnesium Applications
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The reasons leading to these defects were also analyzed and the solutions to eliminate them were put forward. The analytical results revealed that the mold geometry and die casting parameters should be improved in order to get the sound magnesium wheel. Then, the potential defects including the gas entrapments in the middle of the spokes, shrinkages between the rim and the spokes were forecasted. Through calculating temperature field and velocity field during filling and solidification stages, the evolution of temperature distribution and liquid fraction was analyzed.
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In this paper, commercial software for die casting, PAM-CASTâ„¢, was utilized to simulate the low pressure die casting process of magnesium wheel. Nowadays, most current magnesium components in automobiles are made by die casting. Particularly, the usage of magnesium in automotive industry can meet better the need to reduce fuel consumption and CO2 emissions. Magnesium is the lightest metal commonly used in engineering, with various excellent characteristics such as high strength and electromagnetic interference shielding capability. Peng, Yinghong Wang, Yingchun Li, Dayong Zeng, Xiaoqin The Simulation of Magnesium Wheel Low Pressure Die Casting Based on PAM-CASTâ„¢