Abstract
This paper presents a study of distortion and residual stress within a high-pressure die-cast AZ91D component, cast under different processing conditions. The influence of process parameters, i.e., die temperature, cooling time, intensification pressure and first-phase injection speeds, was examined. Distortions were measured using the in-house standard analog quality control fixture. Residual stress depth profiles were measured using a prism hole-drilling method. It was found that the most important process parameter affecting the distortion was intensification pressure and the second most important was temperature difference between the two die halves (fixed and moving side). Tensile residual stresses were found very near the surface. Increasing the intensification pressure resulted in an increased level of tensile residual stresses.
Highlights
High-pressure die casting (HPDC) is an important process for the manufacture of Mg components in the automotive and handheld tools industries
Lee et al.[7] showed that for magnesium alloy porosity is reduced with increasing intensification pressure, but increased with increasing casting second-phase injections speed
The choice of omitting the second-phase injection speed was based on the fact that the dwell time in the shot sleeve is of the order 70 times longer than the duration of the second phase resulting in that the temperature loss during the process is dominated by the shotchamber dwell time
Summary
High-pressure die casting (HPDC) is an important process for the manufacture of Mg components in the automotive and handheld tools industries. A surface with tensile residual stress induced by the casting process will be more prone to fatigue failure than a surface with compressive residual stress.[15] if substantial residual stress exists in a casting, there is potential that at high temperatures residual stress may relax, resulting in part distortion.[16] understanding of residual stress distribution and the distortion pattern of HPDC cast AZ91D parts could enable reduced shape deviation from design specification, through improved process control and better die design This would improve productivity and reduce cost. Analysis of variance (ANOVA) was used to find the effect of casting parameters on the performance characteristics
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