Gas content in high pressure die castings

Wang, Laihua; Turnley, Peter; Savage, Gary

doi:10.1016/j.jmatprotec.2011.03.024

Cited by 51 publications

(21 citation statements)

References 2 publications

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“…그러나 기존의 다이캐스팅 공정 시 캐비티 내부에 형성되는 주조 결함은 내구재와 같은 고강도가 요구되는 부품에 대한 적용을 제한했으며, 이러한 내부 결함 은 대부분은 사출시 혼입되는 공기에 의해 다이캐스팅 주물 내 10~40cc / 100gAl의 많은 가스기포결함을 형성한다 [3][4][5]. 다이캐스팅 공정 시 금형에 갇힌 가스는 용탕이 충전되고 응고된 후에 기포결함의 원인이 되며, 캐비티 및 슬리브 내 에서 충전되는 동안 공기가 혼입되기 쉬우므로 이를 최소화 시킬 필요가 있다 [6,7].…”

Section: 서 론unclassified

Effect of Casting Thickness and Plunger Velocity on Porosity in Al Plate Diecasting

Kang¹,

Park²,

Kim³

et al. 2015

Journal of Korea Foundry Society

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The Al die casting process has been widely used in the manufacturing of automotive parts when the process requires near-net shape casting and a high productive rate. However, porosity arises in the casting process, and this hampers the wider use of this method for the creation of high-durability automotive components. The porosity can be controlled by the shot condition, but, it is critical to set the shot condition in the sleeve, and it remains difficult to optimize the shot condition to avoid air entrapment efficiently. In this study, the 4.5 mm, 2.0 mm plate die castings were fabricated under various shot conditions, such as plunger velocities of 0.7 m/s~3.0 m/s and fast shot set points of the cavity of −25%, 0%, 25%, and 50%. The mold filling behavior of Al melts in the cavity was analyzed by a numerical method. Also, according to the shot conditions, the results of numerical analyses were compared to those of die-casting experiments. The porosity levels of the plate castings were analyzed by X-ray CT images and by density and microstructural analyses. The effects of the porosity on the mechanical properties were analyzed by tensile tests and hardness tests. The simulation results are in good general agreements with the die-casting experimental results. When plunger velocity and fast shot set point are 1.0 m/s and cavity 25% position, castings had optimum condition for good mechanical properties and a low level of porosity.

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Section: 서 론unclassified

Effect of Casting Thickness and Plunger Velocity on Porosity in Al Plate Diecasting

Kang¹,

Park²,

Kim³

et al. 2015

Journal of Korea Foundry Society

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“…Among aluminum-silicon and aluminum-silicon-magnesium based alloys, AlSiMgMn alloys, designated as AA365 (Silafont 36 ® ), usually have good castabilities and excellent mechanical properties [3], and therefore, they are widely used to make automotive structural components by HPDC process [4,5,6,7]. In the conventional die-casting process, the high velocity injection of molten metal unavoidably entraps a certain amount of cavity gas in the material, which results in the formation of porosities in the castings [8,9,10,11]. The porosities are the potential initiation sites of fracture and fatigue failure, which are detrimental to the casting properties and performance [12,13].…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Mechanical Properties of High Vacuum Die-Cast AlSiMgMn Alloys at as-Cast and T6-Treated Conditions

et al. 2019

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Al–Si–Mg based alloys can provide high strength and ductility to satisfy the increasing demands of thin wall castings for automotive applications. This study has investigated the effects of T6 heat-treatment on the microstructures, the local mechanical properties of alloy phases and the fracture behavior of high vacuum die-cast AlSiMgMn alloys using in-situ scanning electron microscopy (SEM) in combination with nano-indentation testing. The microstructures of the alloys at as-cast and T6 treated conditions were compared and analyzed. It is found that the T6 heat treatment plays different roles in affecting the hardness and the Young’s modulus of alloy phases. This study also found that the T6 heat treatment would influence the failure modes of the alloys. The mechanisms of crack propagation in the as-cast and T6 treated alloys were also analyzed and discussed.

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“…High pressure die casting (HPDC) is one of the most commonly used casting method for aluminium alloys [1,3]. HPDC is a cost-effective process widely used to produce components with forming capability of complex shaped castings with fine grain microstructure, as well as excellent surface and excellent dimensional accuracy [3][4][5]. Although the tooling is expensive, the productivity is high and part price is thereby modest.…”

Section: Introductionmentioning

confidence: 99%

Performance Evaluation of Different Air Venting Methods on High Pressure Aluminum Die Casting Process

Altuncu

Doğan

Ekmen³

2019

Acta Phys. Pol. A

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In the automotive industry, die casting technology is used in the production of many parts in series. Due to increased customer demands and reliability expectations, tightness properties are dominant in aluminium alloy based cast parts. In order to acquire the tightness property, it is necessary to control the gas porosity at the casting structure. High pressure die casting aluminium alloy products generally contain gas porosity in certain sizes and ratios due to gas compression during high speed injection of molten metal into the die cavity. Proper die design and evacuation of air in the die and also optimized process parameters need a very critical precaution to reduce the gas porosity. Today, various venting, valve, and vacuum systems are used to facilitate the evacuation of die air. The use of venting systems in the process increases both product quality and process efficiency. In this study, the performance of 3D venting system and mechanical valve performance in high pressure aluminium alloy (AlSi10Mg) casting process with cold chamber were compared on MAGMASOFT high pressure die casting simulation program. As a result of the experimental studies of the 3D vents system, the gas porosity and machine shutdown times can be significantly reduced.

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Gas content in high pressure die castings

Cited by 51 publications

References 2 publications

Effect of Casting Thickness and Plunger Velocity on Porosity in Al Plate Diecasting

Effect of Casting Thickness and Plunger Velocity on Porosity in Al Plate Diecasting

Microstructure and Mechanical Properties of High Vacuum Die-Cast AlSiMgMn Alloys at as-Cast and T6-Treated Conditions

Performance Evaluation of Different Air Venting Methods on High Pressure Aluminum Die Casting Process

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