Development of PentaCast HPDC Technology Using Graphite Inserts

PentaCast位于安大略省斯特拉瑟罗伊，是一家压铸铸造厂，采用高压压铸（HPDC）和钢模以及重力铸造成半永久性模具，生产锌和铝汽车零部件。PentaCast将与温莎大学 ** 的金属铸造和后处理技术小组合作，该小组在包括模具冷却系统在内的冶金工艺的HPDC和快速原型（RP）领域拥有广泛的专业知识和技术能力。PentaCast的目标是成为新型RP方法领域的国内和全球领导者，包括：（1）在钢模具中使用可互换石墨/钢插入件的混合 **HPDC和（2）工厂范围的冶金工艺。为了解决钢模具中石墨/钢嵌件的快速原型制作问题，PentaCast计划投资高速加工 **CNC技术。由大学研究人员申请专利的通用冶金模拟器和分析仪（UMSA）平台将用于合金开发的RP，化学，液体和半固态熔体加工的改进和验证（热处理和化学处理），优化模具热管理参数和铸件热处理，** 确定测试样品的功能特性，所有这些都导致组件功能性能的最大化。石墨模具镶件的RP与UMSA对HPDC工艺的快速物理模拟一起，将显著减少新铸造部件、合金和制造工艺的开发时间和费用。UMSA** 模拟的研发结果还将提供设计超细结构和将航空合金转换为汽车应用所需的热数据。

PentaCast, in Strathroy, ON is a die casting foundry making zinc and aluminum automotive components, using High Pressure Die**Casting (HPDC) with steel molds and gravity cast into semi-permanent molds. The PentaCast will collaborate with the University**of Windsor' Metal Casting and Post Processing Technology group that have an extensive expertise and technical capabilities in**the area of HPDC and Rapid Prototyping (RP) of metallurgical processes including die cooling system.**The PentaCast goal is to become domestic and global leader in the area of novel RP methodology involving both, (1) hybrid**HPDC with interchangeable graphite/steel inserts in a steel die and (2) plant-wide metallurgical processes.**In order to address rapid prototyping of graphite/steel inserts in a steel die, PentaCast plans to invest in a high-speed machining**CNC technology. Patented by the University researchers, the Universal Metallurgical Simulator and Analyzer (UMSA) platform will**be utilized for RP of alloy development, improvements and verification of chemistry, liquid and semi-solid melt processing (thermal**and chemical treatments), optimization of the die thermal management parameters and cast component heat treatment and**determination of test sample functional characteristics all of which leads to maximization of component functional performance.**The RP of graphite die inserts together with the UMSA rapid physical simulations of HPDC processes will significantly reduce**development time and expenses for new cast components, alloys and manufacturing processes. R&D outcomes from the UMSA**simulations will also provide thermal data needed for designing of the ultrafine structures and conversion of the airspace alloys to**automotive applications.