New high-performance composite materials have been successfully developed

On June 2nd, the Joint Research Institute of Foundry and Abrasion Materials successfully developed a new type of high-performance composite material.

The new material is particularly suitable for working under severe abrasive wear conditions, and is particularly suitable for crushed hard, strong abrasive materials. The lifespan of the composite eaves cast from the new high-performance composite material is more than 3 times longer than that of the ordinary eaves. It has broken the record that the wear-resisting casting of new materials has only been able to increase the service life of high-manganese steel castings by up to 1.5 times. This is a leap in the development of new materials in China.

In May 2007, the Joint Institute of Foundry and Wear Materials was established. The institute is jointly established by State Dingsheng Engineering Technology Co., Ltd. and Xi'an Jiaotong University. It represents the highest level of China's wear-resistant materials industry and the current international advanced level. It is dedicated to representing the international science and technology level of wear-resistant materials. The research of extrusion technology, the research of advanced in-situ composite materials, and other major topics in the field of wear-resistant materials have played an unparalleled role in improving the overall level of theoretical research and practical application in this field.

Gravity Casting Parts

"Gravity Die Casting. A permanent mould casting process, where the molten metal is poured from a vessle of ladle into the mould, and cavity fills with no force other than gravity, in a similar manner to the production of sand castings, although filling cn be controlled by tilting the die."

Gravity Die Casting

Sometimes referred to as Permanent Mould, GDC is a repeatable casting process used for non-ferrous alloy parts, typically aluminium, Zinc and Copper Base alloys.

The process differs from HPDC in that Gravity- rather than high pressure- is used to fill the mould with the liquid alloy.

GDC is suited to medium to high volumes products and typically parts are of a heavier sections than HPDC, but thinner sections than sand casting.

There are three key stages in the process.

  1. The heated mould [Die or Tool] is coated with a die release agent. The release agent spray also has a secondary function in that it aids cooling of the mould face after the previous part has been removed from the die.
  2. Molten metal is poured into channels in the tool to allow the material to fill all the extremities of the mould cavity. The metal is either hand poured using steel ladles or dosed using mechanical methods. Typically, there is a mould [down sprue" that allows the alloy to enter the mould cavity from the lower part of the die, reducing the formation of turbulence and subsequent porosity and inclusions in the finished part.
  3. Once the part has cooled sufficiently, the die is opened, either manually or utilising mechanical methods.

Advantages

  • Good dimensional accuracy
  • Smoother cast surface finish than sand casting
  • Improved mechanical properties compared to sand casting
  • Thinner walls can be cast compared to sand casting
  • Reverse draft internal pockets and forms can be cast in using preformed sand core inserts
  • Steel pins and inserts can be cast in to the part
  • Faster production times compared to other processes.
  • Once the tolling is proven, the product quality is very repeatable.
  • Outsourced Tooling setup costs can be lower than sand casting.

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