R.D. Pehlke’s research while affiliated with University of Michigan and other places

In this study, the important role of atomized flow (jet flow) in high pressure die casting manufacture is cited. A series of experimental studies with a water analogue were conducted. It was found that the critical gate velocity for full atomization of water under the conditions of this study was about 19.6 m/s. A formula was used to estimate the critical gate velocity of liquid aluminium by correlating the difficulty of water to atomize with that of liquid aluminum via surface tension and other parameters. As a result, liquid aluminum was found to be about 3.33 times more difficult to atomize than water. Hence, it was estimated that liquid aluminum might be fully atomized at a gate velocity higher than 65 m/ s. Furthermore, based on some reports in die casting practice, it is suggested that atomization in high pressure die casting might not be always regarded as a consistent problem, but might provide some solutions for extremely thin wall die casting manufacturing to explore new markets in the electronics and communications industries.