Abstract
For understanding the processing-microstructure-properties correlation of high pressure die casting (HPDC) AZ91D alloy, 3D reconstruction was carried out to characterize the microstructural morphologies of castings produced by four designed HPDC processes. The influence of different parameters (vacuum, slow-shot speed, fast-shot speed) on porosity volume and morphology, defect band width and average externally solidified crystals (ESCs) size of castings were systematically studied. Microstructural characterization revealed that the defect band width was strongly related with the size and quantity of ESCs, rather than the porosity volume. Meanwhile, ESCs were mainly influenced by the slow-shot speed in shot sleeve (ESCs growth time) and fast-shot speed into the die cavity (shear stress of melt flow). Tensile fracture revealed that cracks easily propagated within the defect bands due to the accumulated ESCs and connected irregular pores, while the cracks were restrained in center zone. The mechanical properties of HPDC castings was inversely proportional to the defect band width, and is not dependent on the average volume fraction porosity.
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