Abstract
Air entrapment defects prevent the heat treatment from improving the mechanical properties of die castings, which limits the die casting of high-performance components. The flow pattern of the filling process is complicated and experimental analysis is difficult in thin-walled complex die castings. In this study, we constructed a shock absorption tower to observe in real-time the filling process of pure aluminum and A380 aluminum alloy at different fast injection speeds. The degree of breakup of pure aluminum was larger than that of A380 during the filling process, which caused the porosity of pure aluminum to be greater than that of the A380 at each observation position. Re-Oh diagrams explained the difference in porosity between the two metals. The porosity in different regions was closely related to the flow state of aluminum liquid. In addition to porosity measurements, we specifically analyzed the relationship between the porosity of the flowback zone, the final filling zone, and the near-tail zone of cylinder. At the same injection velocity, the porosity at flowback zone was greater than that at the final filling position, the porosity at final filling position was larger than that at the near-tail zone of cylinder, and the final filling position changed as the injection velocity changed.
Highlights
High pressure die casting (HPDC), which is a special type of casting method, has been widely used in automotive fields due to its high productivity and its excellent dimensional and shape accuracy [1].Gas-induced porosity is the main limitation and important problem in HPDC [2]
We analyzed predicted the locations and sizes of air entrapment defects combined with porosity measurements and predicted the locationsanalysis)
Sizes of air entrapment defects combined with porosity
Summary
High pressure die casting (HPDC), which is a special type of casting method, has been widely used in automotive fields due to its high productivity and its excellent dimensional and shape accuracy [1].Gas-induced porosity is the main limitation and important problem in HPDC [2]. High pressure die casting (HPDC), which is a special type of casting method, has been widely used in automotive fields due to its high productivity and its excellent dimensional and shape accuracy [1]. The filling time is extremely short, gas trapped during the high-speed injection causes formation of pores, because of the characteristics of “high-speed filling” of die casting [3,4]. The theory and technology of die casting are still immature, especially the actual filling process and gas porosity distribution of die casting. It is of great engineering and theoretical value to study the die casting filling process and to predict the distribution of gas entrapment to improve the performance of die castings. This research will significantly promote the development of lightweight automotive technology
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