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HIP (Hot Isostatic Pressing) is a mature process for the densification of all
cast materials. Until recently, however, it was too expensive to consider for
high volume, commercial applications such as automotive aluminum castings. The
only alternatives for critical structures like steering knuckles and brake calipers
was to resort to 100% x-ray inspection and high scrap rates or to upgrade to squeeze
casting techniques. Both alternatives are expensive in a market that is inherently
very thrifty. High volume aluminum foundries are recently getting "hip" to
a lower cost alternative that will allow them to develop competitive properties
using existing sand and permanent mold foundries for these critical parts. The
cost adder is typically a small fraction of that associated with upgrading to
squeeze casting. The new process was developed by Bodycote HIP and is called "Densal® II + T6". It is a value-added service applied to aluminum castings, which heals internal porosity without distorting complex casting configurations. Ductility and fatigue lives are improved. Bodycote can perform an integrated HIP and heat treatment process on site for high volume foundries. The total cost for HIP and heat treat are typically under $.50/lb at full capacity in an integrated plant. Bodycote developed Densal® over the past 12 years. It is an economical HIP process custom tailored to Al casting. The Densalâ II + T6 process is conducted in a unit specifically designed only for Al castings. High temperature transfer of parts and in-line quench and aging assures a minimum cycle time and cost and maximum throughput. For more information download "Densal® II" from http://hipna.bodycote.com/ |
