Gating system optimization of high pressure die casting thin-wall AlSi10MnMg longitudinal loadbearing beam based on numerical simulation

Abstract

High pressure die casting (HPDC) is a kind of near net shape manufacturing method. However, air entrapment in HPDC parts has serious effects upon the casting quality. In order to reduce the air entrapment defects in a AlSi10MnMg alloy thin-wall longitudinal load-bearing beam produced by HPDC, different gating systems were designed and simulated by software Flow-3D to evaluate the entrapped air. Simulation results showed that when the beam is produced by the original designed gating system with a middle ingate, there exist obvious air entrapments in the critical area; the volume of air entrapment was reduced by replacing the middle ingate to an overflow well, and the filling of molten metal became more stable. When the middle ingate was removed for further improvement, the volume of air entrapment was decreased drastically. The parts with glossy surface and good microstructure have been successfully produced by using the final optimized gating system based on simulation results.