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Development of an Alloy for High Pressure Die Cast Pistons

Article of Honda R&D Technical Review Vol.13 No.1

Summary

High pressure die casting material was developed for the use of pistons in various mass-produced, small, general-purpose engines. This new material enables a significant reduction in casting tact time, allows a continuous line through the casting and machining processes, which is impossible to achieve by the permanent mold gravity die casting method (GDC), and contributes to production cost reduction. This material provides a material hardness of HRB65, which is equivalent to the material used in conventional methods, due to the high speed filling of the molten metal into the dies and the quick solidification of it. The material also accomplishes the high temperature durability requirements after undergoing a short T5 process. For the stabilization of the material properties in mass production, various alloy prototypes were produced and evaluated on strength, residual stress, seizure, microstructure, and actual engine durability in order to determine the optimal alloy composition.

Reference

(1) Suzuki, T., Hojo, H., Inoue, S., Moriyama, H. and Fujinaga, Y.: Development of General Purpose OHC Engine with Built-in Timing Belt, Honda R&D Technical Review, Vol. 10, pp. 122-127 (1998).
(2) Shiga, M., Nishida, T., Ryu, Y., Tugekawa, T., Higashi, K. and Maeda, T.: Development of All Position-Operatable Small Four-Stroke Engine, SAE Paper 972104.
(3) Fukai, S., Takeuchi, K. and Tanaka, E.: A Study on the Elevated-Temperature Strengths of AC8A and AC8B Aluminum Cast Alloys for Piston, Sumitomo Light Metal Industries Technical Report, Vol. 4, No. 4, pp. 17-42 (1963).

Author (organization or company)

Norimasa TAKASAKI(Asaka Higashi R&D Center)、Yuko YOSHIMURA(Asaka Higashi R&D Center)、Kazuyoshi SATO(Asaka Higashi R&D Center)、Yukio SUGIMOTO(Asaka Higashi R&D Center)、Takanori SATO(Asaka Higashi R&D Center)

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