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Thixotropic fluids flow when sheared, but thicken when standing. [3] The potential for this type of process was first recognized in the early 1970s. [3] Its three variants are thixocasting, rheocasting, and thixomolding. SIMA refers to a specialized process to prepare aluminum alloys for thixocasting using hot and cold working. [clarification ...
Typical tolerances are 0.4 mm for the first 25 mm (0.98 in) for the first inch) and 0.02 mm for each additional centimeter (0.002 in per in); if the dimension crosses the parting line add an additional 0.25 mm (0.0098 in). Typical surface finishes are 2.5 to 7.5 μm (100–250 μin) RMS. A draft of 2 to 3° is required.
Shell molding is similar to sand casting, but the molding cavity is formed by a hardened "shell" of sand instead of a flask filled with sand. The sand used is finer than sand casting sand and is mixed with a resin so that it can be heated by the pattern and hardened into a shell around the pattern. Because of the resin and finer sand, it gives ...
General Motors' first product using these processes was the 4.3 L, V-6 diesel cylinder head, which were made in 1981 at Massena, New York. [11] A study found in 1997 that evaporative-pattern casting processes accounted for approximately 140,000 tons of aluminium casting in the United States.
Generally, the casting materials used for competing processes like metal die casting and injection molding are similar, but not suitable for spin casting. For example, a typical zinc die-casting alloy such as Zamak 3 can be used but will solidify too rapidly from a molten state when cast with centrifugal force.
If the cross-section is asymmetrical, adjacent sections should be as close to the same size as possible. Sharp corners should be avoided; for aluminium and magnesium the minimum radius should be 0.4 mm (1/64 in) and for steel corners should be 0.75 mm (0.030 in) and fillets should be 3 mm (0.12 in). The following table lists the minimum cross ...
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