Open Lattice Casting Support for Thermal Treatment Sagging
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Solution Overview
Problem
Thermal treatment of thin wall aluminum alloy castings formed in the high pressure die cast (HPDC) process often results in defective parts and high scrap rates due to uneven thermal applications, leading to dimensional distortions and sagging, which are exacerbated by traditional full position fixtures that impede fluid flow and create internal stresses.
Innovation Solution
A casting support system comprising a tray with vertically-oriented support plates forming an open lattice structure that allows thermal fluids to pass through while securely supporting castings, preventing sagging and ensuring uniform thermal treatment by aligning the casting to facilitate even heat transfer across all surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If full position fixtures are used to rigidly constrain castings during thermal treatment, then sagging and dimensional distortion are reduced, but thermal fluid flow is impeded and temperature gradients are exacerbated
Solution Approach 1:
The fixture is divided into multiple discrete support elements (support plates with shaped profiles) rather than a continuous rigid structure. These segmented supports are strategically positioned to constrain the casting at key locations while leaving gaps for thermal fluid access, thus preventing sagging without impeding overall heat treatment uniformity
Solution Approach 2:
The support structure provides localized constraint only where needed to prevent sagging, rather than rigidly constraining the entire casting. The shaped profiles contact the casting underside at specific regions, allowing thermal fluids to access most surfaces while providing targeted mechanical support to maintain dimensional tolerance
2Stability of the object's composition
If full position fixtures are used to prevent sagging, then casting stability is improved, but internal stresses increase due to blocked thermal fluid flow
Solution Approach 1:
The continuous rigid fixture is segmented into discrete support plates that provide stability only where structurally necessary. This segmentation allows thermal fluids to flow freely around and through the support structure, preventing the buildup of internal stresses while maintaining casting stability during the thermal treatment process
3Stability of the object's composition
If traditional fixtures are used to support castings, then sagging is prevented, but thermal treatment uniformity deteriorates due to impeded fluid flow
Solution Approach 1:
The fixture provides mechanical support with local quality - concentrated at specific support points where sagging prevention is needed - while maintaining thermal treatment uniformity through strategic positioning that allows comprehensive thermal fluid access to all casting surfaces
Solution Approach 2:
The support structure is designed with vertical dimension consideration, with support plates extending upward from the tray to contact the casting underside. This vertical arrangement provides sagging prevention while maintaining horizontal openness for thermal fluid circulation, effectively using the vertical dimension for mechanical support without compromising thermal access in the horizontal plane
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively reduces internal temperature gradients and prevents sagging, ensuring castings meet dimensional tolerances by providing targeted support and unobstructed fluid access, thereby minimizing distortions and scrap rates during solution heat treatment, quenching, and aging processes.
Implementation Method 1
The plurality of support plates form an open lattice having a plurality of top edges that together define an open support surface that is substantially complementary with an underside surface of a casting, and that is configured to loosely support the casting atop the lattice
Implementation Method 2
thermal fluids to pass through while securely supporting castings, preventing sagging and ensuring uniform thermal treatment
Data Source
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AI summary
A system for supporting castings during thermal treatments, such as solution heat treatment, quenching and aging, that includes a tray defining a horizontal base plane and having a plurality of tray openings therethrough, and a fixture extending over one or more of the tray openings. The fixture is formed by a plurality of support plates oriented vertically with lower portions extending across the tray opening and top edges extending above the tray opening with shaped profiles along the lengths thereof. The plurality of support plates form an open lattice having a plurality of top edges that together define an open support surface that is substantially complementary with an underside surface of a casting and configured to loosely support the casting atop the lattice and align the casting in space above the tray opening.