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By Alan Kaye

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On account of the long freezing range of this alloy, General Motors applied their Acurad process16. This involves a double plunger method of injection so that an intensification of pressure allows additional metal to be fed during the alloy's freezing. The dies were provided with a large gate area, to ensure that the gate metal was the last to freeze. 5 seconds, was considerably slower than in conventional pressure die casting. The cooling of the die was arranged to ensure solidification from the furthest point of the die progressively to the gate.

5 81 (1926) 6. ELLIOTT, R. Eutectic solidification. International Metals Reviews No. 219, pp. 161-186 (1977) 7. ELLIOTT, R. Eutectic solidification (in preparation) 8. W. Fundamentals of modification in the aluminium-silicon system. Journal of the Institute of Metals, 92, 367 (1963-64) 9. E. The modification of aluminium-silicon alloys by sodium. Journal of the Institute of Metals, 86,393 (1957-58) 10. ; HELLAWELL, A. The structure of modified aluminium-silicon eutectic alloy Journal of the Institute of Metals, 95,377(1967) 11.

Shrinkage cavities may be caused during solidification, or by porosity from entrapped gas in the molten metal, in the dies or in the laminations. Partially cracked bars and small shrinkage cavities reduce the conductivity of the squirrel cage and hence the performance of the motor. Small rotors for domestic appliances have varying numbers of laminations, depending on the size and power of the motor, but the weight of the lamination pack is always more than that of the die cast metal. Some plants are fully mechanized while in others one man is responsible for a sequence of operations.

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