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Squeeze Casting of Steel

Squeeze Casting of Steel

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INTRODUCTION
The conventional casting and metal forming processes often result in oversize and heavy weapon components, which then must be extensively finish-machined. Since the machining cost is then a large fraction of the overall cost, this is an area for potential cost reduction in fabricating weapon components. In sand castings, much expense is also associated with the preparation of molds and trimming of the castings .

TABLE OF CONTENTS
FOREWORD
1. INTRODUCTION 1
2. TECHNICAL DISCUSSION 3
2.1 Squeeze Casting -- Process Parameters and Advantages 3
2.2 Published Work ...... 7
3. PART GEOMETRY AND TOOLING 12
3.1 Receiver Base 12
3.1.1 Part Geometry and Current Method of Production 12
3.1.2 Target as a Squeeze Casting 16
3.1.3 Design and Operation of the Die 16
3.2 Barrel Support 19
3.2.1 Part Geometry and Current Method of Production 19
3.2.2 Target as a Squeeze Casting 19
3.2.3 Design and Operation of the Die 25
3.3 Die Material * 28
3.3.1 Die Material Selection 28
3.3.2 Dimensional Considerations 30
4. EQUIPMENT AND PROCEDURAL DETAILS 31
4.1 Hydraulic Press 31
4.2 Melting and Melt Transfer Facilities 32
4.3 Melting Technique, Composition Control, and Melt Transfer 33
4.4 Die Heating 38 4.5 Die Pretreatment and Mold Wash ............ 38
4.6 Experimental Procedure .... 40
4.6.1 Receiver Base 40
4.6.2 Barrel Support 42
5.1 Receiver Base Die 44
5.1.1 Observations During First Squeeze Casting Series. ...... 44
5.1.2 Tooling Modifications 49 5.1.3 Final Squeeze Casting Series. ... 57
5.2 Barrel Support Die 63
5.2.1 Observations During First Series of Tests 63
5.2.2 Tooling Modifications and Second Series 67
5.2.3 Final Squeeze Casting Series. ... 79
6.1 Surface Quality and Dimensional Inspection . . 90
6.2 Internal Integrity 97
6.3 Heat Treatment, Mechanical Properties, and Composition 104
6.4 Potential for Cost Reduction 112
7.1 Surface Quality and Dimensional Inspection 115
7.2 Internal Integrity 120
7.3 Mechanical Properties and Chemistry. . . . 125
7.4 Comparison of Performance of Various Die Materials 130
7.5 Effect of Part Geometry on Quality .... 134
7.6 Effect of Process Variables on Quality . . 137
7.7 Potential for Cost Reduction 141
8. PRELIMINARY PROCESS SPECIFICATION 142
8.1 Receiver Base. . 142
8.2 Barrel Support 145
9.1 Accomplishments and Main Results 147
9.2 Comments on Large-Scale Production. . . . 150
REFERENCES 152 vi
LIST OF TABLES

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