Energy and Resource Efficiency in Aluminium Die Casting by Tim Heinemann

By Tim Heinemann

This monograph offers a field-proven method of research commercial creation with a cross-company scope in addition to concerning all hierarchical approach degrees of producing companies. The publication exemplifies this strategy within the context of aluminum die casting, and provides a collection of measures which enable a 30 percentage power aid alongside the worth chain. the objective viewers essentially includes researchers and specialists within the box however the ebook can also be helpful for graduate students.

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13 % of the German aluminium product demand (ca. 3,427,000 t). com 2014). After this introduction of global aluminium flows and German aluminium production volumes, the specific aluminium die casting value chain will be described in the following sections—starting with the introduction of raw material and secondary material input flows. 3 Raw and Secondary Material Input Flows Due to the fact that the aluminium die casting value chain has to rely on further upstream activities, which provide it with input materials and have an impact on the performance of the overall value chain, this section provides an overview over the raw and secondary material input flows like the generation of primary aluminium and the processed secondary aluminium fractions.

Due to the danger of potential gas entrapments of die casted parts, a temperature of about 250 °C should not be exceeded to avoid the formation of blisters. The heat treatment gets done preferably in convection ovens which can control a temperature level at a maximum deviation of 5 °C from the target temperature (Honsel 2014; DIN EN 515 1993). The ovens can be operated continuously via transfer lines, or as batch-type furnaces—depending on the batch size of the individual product (Kleine and Heinemann 2013).

The most important elements of the die casting cell will be introduced in the following section. The die casting machine can be broken down into three main components (Hoffmann and Jordi 2013b; Brunhuber 1980): Pump group or power unit, clamping unit, injection system. The pump group delivers the hydraulic pressure, which is needed to operate the moving parts of the die casting machines. An electric motor powers pumps that compress hydraulic fluids up to pressure levels of 160–210 bars. The clamping unit moves and closes the die casting mould.

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