Technology

FET Faculty (Engineering & Technology)

MMU Multimedia University, Malaysia

Counter
l Solidification of the liquid metal at
Pressure Casting Technique high pressure
l High feeding pressure during the
for Aluminium Foundries back feed phase
l Controlled and low turbulence
mold filling
Counter Pressure Casting l High degree of automation
System
Counter pressure casting is a

C
ounter Pressure Casting
technique uses a
combination of pressure and
counter pressure to control the liquid
metal filling inside the mold. The
molten metal is continuously subjected
to increased pressure during mold
filling, which reduces precipitation of
gases. During solidification and the
shrinkage of the metal, the pressure is
maintained to prevent the formation of
porosity and cavities. The process is
shown in Figure-1and Figure-2.
Counter pressure casting
technology is a modern casting
technique for producing light weight
engineering parts subjected to high
stress in the automotive and vehicle
fabrication industry.
The process features are as
follows:
technique which is used for the
production of extremely high quality
aluminium castings. The basic principle
is similar to that for low pressure die
casting. The primary difference is that
in this process not only the furnace is
pressurized, but also the permanent
mold area. These two factors result in
an enhanced quality of the casting
microstructure and to attain better
properties. This process is well suited
as the production process of choice for
highly stressed safety components, for
those used in the vehicle
manufacturing industry which
produces wheel carriers and swivel
bearings. In addition to enhanced
quality and a higher degree of
automation and short cycle times, the
counter pressure technique also
provides a higher material yield than

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December 2012
 FIG. 1 : SCHEMATIC SKETCH OF COUNTER PRESSURE CASTING SYSTEM
FIG. 2 : PRINCIPLE OF COUNTER PRESSURE CASTING PROCESS
the conventional permanent mold
casting process. This process reveals
new possibilities for control and
monitoring of the processes during
shape and structure formation of
aluminium castings. Products of
improved mechanical, physical
properties are achieved. In the
conditions of higher pressure, castings
solidify faster and this provides higher
as compared to the other casting
methods. The CNC control of the
casting process ensures the high
quality of the products, possibility for
quick adjustment and readjustment of
the equipment, elimination of the
human factor during the production
process. This method increases the
plasticity two to three times and the
strength and hardness with 20 % to 30
% at the same time. This results in a
high reserve of operating strength of
the parts, which is extremely important
in the airplane building industry.
Counter pressure machines enable
aluminium casting manufacturers to
produce lighter yet stronger castings,
at the same time significantly lowering
production costs. Replacing
conventional low pressure casting
methods, this next-generation
technology is the perfect solution for
highly stressed, safety critical
components, in particular a car chassis
wheels, various steering knuckles and
control arms. Counter pressure
machines are built with superior quality
products and components.
Counter Pressure Product And
Process Advantages
Prevents shrinkage
l
Lower
l porosity and micro
porosity
lHigher mechanical properties
l Superior performance
characteristics
lWeight saving
l Higher quality surface finish after
machining
lReduced costs
lHigher yield
lShorter cycles
lIncreased productivity
lCost effective volume production
lSuited for rapid prototyping
Special Features of Counter
Pressure Casting Process
v The casting rate depends not on
the pressure exerted upon the melt but
on the difference between pressure
and counter pressure.
v The casting rate in contrast to
other methods can be controlled
precisely and regulated in a large range
by changing of the pressures.
v The appropriate casting rate and
heat removal provide possibilities for
oriented crystallization to run under
the action of higher pressure. In this
case the counter pressure is used as
infiltrating pressure decreasing
considerably the porosity in the
castings.
v The high gas counter pressure that
acts in the pores of the sand molds
balances the pressure exercised by the
melt on the mold walls. Due to this in
gas counter pressure casting any
known in the casting practice molds
and cores can be used
Comparison of Counter
Technology

Pressure Casting Process with Other Casting Techniques in Terms Big size parts are produced.
l
of Mechanical Properties Components
l with complex
TABLE -1 : COMPARISON OF MECHANICAL PROPERTIES WITH OTHER CASTING TECHNIQUES combination of thin and thick sections
are produced.
Ultimate Yield
Name of the Casting Technique Tensile Strength (Ksi) Strength (ksi) Elongation (%) l Castings subjected to high
dynamic and cyclic loads, in particular
Sand Casting 46 38 10
parts for vacuum technology
Vacuum Pressure Casting 46.9 35 11.3 l lParts subjected to high
Squeeze Casting 45.3 35 11 temperatures.
Counter Pressure Casting 48.5 35 14.3 l Car building and transport
Advantages of Counter machines are produced.
as well and protective gases could be
Pressure Casting Process used with success. l It is used to produce parts for
Counter pressure suppresses and application in hydraulic and pneumatic
v v Precise control of the rate of
reduces the release of the gases systems.
casting and filling the die. Rate of
present in the melt keeping them in a casting does not depend on the l Electronic and electrical industry;
dissolved state thus eliminating the gas pressure acting on the melt. l It is applied in airplane building
porosity in the casting. v Precise control of the mould industries.
v The solidification of the metal in filling time. Accurate proportioning of Conclusions
the die cavity proceeds, being under the mechanical energy of the flowing Counter pressure casting is an
the action of the gas pressure in the die melt required filling the mould without established casting process for the
housing and that of the melt pressure at turbulence and breaking the melt free production of cast aluminium
the die inlet. surface. Increasing the pressure components of the highest quality. It is
v Improves the conditions for melt difference in the end of the die filling in similar to conventional low pressure
infiltration and efficient feeding of the order to obtain a better reproduction. casting but has been modified and
casting and prevent the formation of
the associated with shrinkage of the
metal defects like macro porosity and
cavities.
v Improves conditions to eliminate
or reduce micro porosity, result of
better infiltration of the melt between
arising crystallites and plastic micro
deformation them in the process of
crystallization.
v Prolong time of contact between
die and solidifying metal in die cavity
before creation the shrink gap increase
the depth of fine macro structure result
of longer intensive heat transfer to die.
That increase the mechanical
properties of the cast material and
combined with above advantages
improve structural strength of the
casting.
v An integral structure can be
obtained even in thick sections in the
upper part of castings without the use
of risers. If, however, small risers are
v Casting in sand moulds and in optimized to allow cost effective
used in some cases, they work under
permanent moulds with sand cores production of cast chassis components
the same gas pressure, their efficiency
without any danger of their displaying outstanding mechanical
being increased many times. That
destruction, regardless of the applied properties.
makes the yield of usable castings from
working pressure. Acknowledgement
the metal poured very high.
v Realization of directional The author expresses his thanks to the
v Since the whole casting process
solidification by suitable changes in the Faculty of Engineering and Technology,
takes place in closed vessels, the
mould filling speed. FET, MMU, Multimedia University, Melaka
counter-pressure casting technology
provides much better working Applications of Counter Campus, Bukit Beruang, 75450, Melaka,
conditions and minimizes air pollution Pressure Casting System Malaysia.

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December 2012