Energy Consumption of Die Casting Operations

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Molten metal processing is inherently energy intensive and roughly 25% of the cost of die-cast products can be traced to some form of energy consumption [1]. The obvious major energy requirements are for melting and holding molten alloy in preparation for casting. The proper selection and maintenance of melting and holding equipment are clearly important factors in minimizing energy consumption in die-casting operations [2]. In addition to energy consumption, furnace selection also influences metal loss due to oxidation, metal quality, and maintenance requirements. Other important factors influencing energy consumption in a die-casting facility include geographic location, alloy(s) cast, starting form ... continued below

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Brevick, Jerald; Mount-Campbell, clark & Mobley, Carroll March 15, 2004.

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Description

Molten metal processing is inherently energy intensive and roughly 25% of the cost of die-cast products can be traced to some form of energy consumption [1]. The obvious major energy requirements are for melting and holding molten alloy in preparation for casting. The proper selection and maintenance of melting and holding equipment are clearly important factors in minimizing energy consumption in die-casting operations [2]. In addition to energy consumption, furnace selection also influences metal loss due to oxidation, metal quality, and maintenance requirements. Other important factors influencing energy consumption in a die-casting facility include geographic location, alloy(s) cast, starting form of alloy (solid or liquid), overall process flow, casting yield, scrap rate, cycle times, number of shifts per day, days of operation per month, type and size of die-casting form of alloy (solid or liquid), overall process flow, casting yield, scrap rate, cycle times, number of shifts per day, days of operation per month, type and size of die-casting machine, related equipment (robots, trim presses), and downstream processing (machining, plating, assembly, etc.). Each of these factors also may influence the casting quality and productivity of a die-casting enterprise. In a die-casting enterprise, decisions regarding these issues are made frequently and are based on a large number of factors. Therefore, it is not surprising that energy consumption can vary significantly from one die-casting enterprise to the next, and within a single enterprise as function of time.

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OSTI as DE00822409

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  • Other Information: PBD: 15 Mar 2004

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  • Report No.: DOE/ID/13843
  • Grant Number: FC07-00ID13843
  • DOI: 10.2172/822409 | External Link
  • Office of Scientific & Technical Information Report Number: 822409
  • Archival Resource Key: ark:/67531/metadc782777

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Office of Scientific & Technical Information Technical Reports

Reports, articles and other documents harvested from the Office of Scientific and Technical Information.

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  • March 15, 2004

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  • Dec. 3, 2015, 9:30 a.m.

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  • Jan. 3, 2017, 12:22 p.m.

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Brevick, Jerald; Mount-Campbell, clark & Mobley, Carroll. Energy Consumption of Die Casting Operations, report, March 15, 2004; United States. (digital.library.unt.edu/ark:/67531/metadc782777/: accessed April 26, 2018), University of North Texas Libraries, Digital Library, digital.library.unt.edu; crediting UNT Libraries Government Documents Department.