By Alan Kaye
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Extra resources for Die Casting Metallurgy
The latent heat is 93 cal/g. The amount of heat required to bring one gram of aluminium—silicon—copper alloy to casting temperature can be divided into the following stages: 1. 25) x temperature difference (570°C) 2. Converting the solid metal at melting point to liquid mass (1 g) x latent heat (93 cal/g) 93 cal 3. 25) x temperature increase (70°C) 18 cal This makes a total of 253 cal/g, or 253000kcal/tonne. The heat capacity of fuel oil is measured in BTUs, electric power in kWh and gas in therms.
The problems of converting a cast iron component to an aluminium alloy pressure die casting are illustrated by the efforts to produce inlet manifolds. The undercut portions of these manifolds in cast iron were previously made by sand cores and in most cases these curved passageways are difficult or impossible to form by metal cores. There have been exceptions; for example in 1962 the inlet manifold of the Hillman 'Imp' was 44 Aluminium as a substitute for cast iron 45 geometrically designed with a complex series of core movements which enabled it to be produced as a pressure die casting, although at a rather low speed.
Future mass production of die cast inlet manifolds will be stimulated if the castings are made free from microporosity, which causes the risk of weld seam leakage. R. Cristman referred to above suggests that the pore-free process, which will be discussed on page 235 permit die cast multi-piece components such as inlet manifolds to be joined by welding without the danger of leakage. In spite of the savings in fuel to be achieved by reducing the weight of cars, the amount of energy required to produce aluminium versus iron, must be taken into con sideration and, in the short term, iron has the advantage.