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CSIR-Central Mechanical Engineering Research Institute M G Avenue, Durgapur-713209, India Workshop on Rheo Pressure Die Casting Technology 25 th February, 2014 Organized by CSIR-CMERI, Durgapur in association with IISc, Bangalore and Jadavpur University, Kolkata ABOUT CSIR-CMERI CSIR-Central Mechanical Engineering Research Institute (CMERI) is a premier R&D laboratory in the field of mechanical and allied engineering. The dedicated team of qualified professionals of CSIR-CMERI provides technological solutions for poverty alleviation, societal improvement, energy security, food security, etc. The frontline research in the varied areas related to mechanical engineering is being carried out in CSIR-CMERI. The cutting edge R&D programmes in the interdisciplinary areas like Micro systems technology, cybernetics, Advanced Manufacturing Technologies (AMT) are presently being pursued at CSIR-CMERI. ABOUT NNMT GROUP Near Net shape Manufacturing Technologies (NNMT) group is actively involved in component development through advanced material processing technique. Solidification processing of ferrous and non-ferrous material is the core strength of this group for producing near net shape component in order to cater in-house prototype development as well as outside industries requirement. NNMT group has been pioneer in developing Metal Injection Moulding (MIM) technique in India. MIM technique is capable of producing small components with intricate profile and finer details. Present demand in the high strength to weight ratio of the component has led to the development of Rheo Pressure Die Casting (RPDC) of Al and their composites. RPDC is one of the best alternative for production of component through solidification processing. An integrated unit for Rheo Pressure Die Casting System has been developed at NNMT group to meet the present demand. Apart from the above mentioned techniques a layer by layer metal deposition system using laser to produce components, which is otherwise difficult to manufacture though conventional technique, is also being pursued at NNMT group of CSIR-CMERI. Thus NNMT group is in a track towards the forefront research of the country. RHEO PRESSURE DIE CASTING (RPDC) The focus of the foundry industry is gradually being shifted towards the modern casting processes to produce critical components with improved performance. In this domain of advanced manufacturing technique, Semi Solid Manufacturing (SSM) technique is a relatively new process in which metallic alloys are cast at a temperature between solidus and liquidus unlike conventional casting processes. In SSM technique a unique globular and non-dendritic structure surrounded by nearly eutectic liquid is formed. Due to this typical microstructure the partially solidified metal slurry shows a significantly low viscosity and deform homogeneously. This new technology is now widely accepted for production of commercial components with high casting integrity and excellent properties. There are several advantages of RPDC technique over conventional casting processes like less shrinkage, porosity, formability of thin-walled parts, superior mechanical properties, reduction in machining and tooling costs. Because of the advantages listed above, RPDC process is ideally suited for producing a wide range of components for automotive, aerospace and structural applications. The most widely used SSM techniques that are currently being pursued worldwide are (a) Thixocasting and (b) Rheocasting. In India, apart from the National Facility for Semi Solid Forming (NFSSF) at IISc on the Thixocasting process, no major facility for these new processes are setup. In line with the above, Department of Science and Technology (DST), New Delhi, along with CSIR have granted a project entitled “Facility for Rheo- Pressure Die Casting” to CSIR-CMERI in association
