Abstract
Die soldering of die castings is a serious problem in the aluminum casting industry. The precise mechanism, the influence of the alloy composition, and the options for prevention have not yet been fully elaborated. A well-established solution for alloys with low iron content is the addition of manganese. However, up to 0.8 wt.% is necessary, which increases the amount of brittle phases in the material and consequently reduces ductility. Immersion tests with 1.2343 tool steel and pure aluminum as well as a hypoeutectic AlSi-alloy with Mn, Mo, Co, and Cr additions were carried out to systematically investigate the formation of die soldering. Three different intermetallic layers and a scattered granular intermetallic phase formed at the interface between steel and Al-alloy after immersion into the melt for a duration of 6 min at 710 °C. The combined presence of the irregular, needle-shaped β-Al5FeSi phase and the surrounding alloy was responsible for the bond between the two components. Mn and Mo inhibited the formation of the β-phase, and instead promoted the αC-Al15(Fe,X)3Si2 phase. This led to an evenly running boundary to the AlSi-alloy and thus prevented bonding. Cr has proven to be the most efficient addition against die soldering, with 0.2 wt.% being sufficient. Contrary to the other elements investigated, Cr also reduced the thickness of the intermetallic interface.
Highlights
High-pressure die casting (HPDC) is one of the most common methods for mass production of aluminum alloy parts
FTiogoulrSet3eaelsahnodwPsuthree Aevluolmutiniounmof the intermetallic layer thickness at the interface after atiAhifmmtasevmersesFhie.miiorAngswmudisonriescne,hratso3othiefawoedtnshlnatheo,hyotfa1ehwtt.r2ehtst3ehhl4atei1h3yc.fkee2toorn3reo4etmvh3lsosiastclttoiukeinooentcinllerosiesnontsaeftsoioetenlfhdtciehtrnhaeeitcenaopcstiouetenhrrdrtdmeeeairapnecmltucguaoremlterltoidaicaanlillnluuipacgmmyaltreaioarmnysbaueeoimrpslltiatacahmrtfcaiucodebnklmoitfcnlfabtieeictiorsnfedsnueni.adfntVftcedpattriihrrepooineonpctu.ieinndssVgstisaeptotrrpuiiffmoaiddnucieigeesfss-. sftuusdiioens ahnadvechinedmiciacateldretahcattiothneaftotrhmearteiaocntioofnthfreoinntte[6r,m13e,t1a6ll]i.c layers is a combined process of diffusion and chemical reaction at the reaction front [6,13,16]
By taking the results of the binary system into account, it can be concluded that the combination of the irregular, needlelike interface of the β-Al5FeSi phase and the surrounding alloy was responsible for the metallurgical bond
Summary
High-pressure die casting (HPDC) is one of the most common methods for mass production of aluminum alloy parts. Because of the low cycle time of the casting operation, as well as the good mechanical properties and castability, HPDC possesses a high productivity and operational cost efficiency [1]. This makes it popular in various fields of the global industry. Die soldering is one of the main die failure modes, leading to malfunctioning of die inserts, production downtimes, and damage to the casting components This phenomenon occurs when the liquid aluminum melt reacts with the die to form a solid compound, which prevents faultless demolding. Ficorrosmtriucrcotustrraulcsttuurdailesst,utdheieys,wthereeyswecetrioenseedctaiotnfoeudraptofsoiutironpsosfoitriobnesttfeorr sbtaetitsetricsst,athisetnicsm, othuenntemd,ogurnotuendd, g, aronudnpdo,laisnhdedp.oDliseheepde.tDcheienpg ewtcahsincognwduasctceodnwduitchteNdawOiHth sNolauOtiHonsfoolur t5iomnifnoart55m0 ◦inC.aOt 5p0ti°cCal. mOpictriocascl ompiycrwosacsoupsyedwtaos iunsveedsttiogaintevtehsteigmaoterpthheolmogoyropfhtohleoignyteorfmthetealilnictelramyeertas.llTichleayinetresr.mThetealilnicteprmhaesteasllwiceprheaasneaslywzeerde uasnianlgyzaefideuldsienmg iassfiioelnd secmanisnsiinogneslecactnrnoinnmg ieclreocstcroonpem(ZicErIoSsScoSpIGe M(ZAEIVSPS, OSIbGeMrkAochVePn,, OGbeermrkaoncyh)enin, cGoemrmbiannayti)onin wcoitmhbainnaOtixofnorwditIhnsatnruOmxefnotrsdXIn-MstaruxmdeentetcstXor-M(OaxxfdoredteIcntosrtr(uOmxefonrtds pInlcs.t,rAumbienngtds opnlc, .U, AKb).Tinhgedboanck, sUcKat)t.erTheleecbtarocknsdcaettteecrtoerlewctarsounsdedetetoctdoirscwerans buestewdeteondthisecelarnyebrse.twTheeenphthaeselsayaenrds. lTayheerpshwaesrees iadnedntlaifiyeedrsbwyeerneeirdgeyn-tdifisiepderbsyiveenXer-grayy-dsipsepcetrrsoisvceoXp-yra(EyDspSe) catnrodsbcoypcyom(EpDaSr)isaonnd wbyithcodmatpaairnisloitnerwatituhred.aTtoa iinnvleitsetriagtauteret.hTeoeifnfevcetsotifgtahtee athlleoyeifnfegcteloefmthenetasl,lEoyDinSgmealpempienngtss, wEeDrSe cmaarrpiepdinogustw. ere carried out
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