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Using HIP to Improve Aluminum Castings

Hot isostatic pressing could augment selected aluminum gravity casting.

With more design opportunities arising every year for aluminum casting, commercial demand for engineered cast components continues to increase. One large market niche falls with high-integrity aluminum castings for aerospace and automotive markets.

However, a major limitation of aluminum castings for these applications is the potential presence of porosity as the melt solidifies and contracts. Internal shrinkage porosity is a common fatigue life-limiting factor, and this can be true for very small amounts of porosity in high-quality castings and for more prevalent internal voids in parts of lower quality castings.

One solution to eliminate internal porosity is hot isostatic pressing (HIP), which bonds materials together in cast components. The process applies high pressure to the exterior of a casting or metal powder billet via a high temperature inert gas. Sand, permanent mold and investment casting are the most common casting methods that respond well to HIP.

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