Die Casting Metallurgy by Alan Kaye

By Alan Kaye

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Melting equipment for aluminium alloys 53 Bulk melting Companies that purchase their aluminium alloy as ingot and recycle their own pro­ cess returns select an area near the foundry where the metal is bulk melted and then distributed to the individual die casting stations. Companies which take molten metal deliveries need to have additional equipment for remelting scrap and runners, although a few manufacturers return such material to secondary metal refiners for melting, cleaning, chemical analysis and re-delivery.

The laminations have a central hole for the rotor shaft and the pack is usually skewed about the shaft to give an angle with respect to the conductor bars. The pack of 40 Aluminium alloy die castings laminations is mounted on a removable mandrel or occasionally the motor shaft itself, skewing the pack to the required angle, enclosing the assembly in a die. Molten aluminium is injected so that it runs into the slots to form the conductor bars and into the cavities at either end to form the end rings, which may also incorporate cooling fins.

A large and specialized industry is involved with the die casting of rotors in high conductivity aluminium for these small motors. Larger rotors 21 ' 22 , sometimes up to 350mm in diameter, are die cast for use in submersible pumps, lift motors and many other kinds of industrial drive motors. Generally motors up to 15 HP have pressure die cast rotors while larger ones may be either centrifugally cast, permanent mould or low pressure cast. 65 mm thick) and electrically conductive bars running through the slots.

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