Abstract
The resulting quality of castings indicates the correlation of the design of the mold inlet system and the setting of technological parameters of casting. In this study, the influence of design solutions of the inlet system in a pressure mold on the properties of Al-Si castings was analyzed by computer modelling and subsequently verified experimentally. In the process of computer simulation, the design solutions of the inlet system, the mode of filling the mold depending on the formation of the casting and the homogeneity of the casting represented by the formation of shrinkages were assessed. In the experimental part, homogeneity was monitored by X-ray analysis by evaluating the integrity of the casting and the presence of pores. Mechanical properties such as permanent deformation and surface hardness of castings were determined experimentally, depending on the height of the inlet notch. The height of the inlet notch has been shown to be a key factor, significantly influencing the properties of the die-cast parts and influencing the speed and filling mode of the mold cavity. At the same time, a significant correlation between porosity and mechanical properties of castings is demonstrated. With the increasing share of porosity, the values of permanent deformation of castings increased. It is shown that the surface hardness of castings does not depend on the integrity of the castings but on the degree of subcooling of the melt in contact with the mold and the formation of a fine-grained structure in the peripheral zones of the casting.
Highlights
From the point of view of the influence of the structure of the gating system of die casting mold upon the die-cast part quality, the most significant parameters affect the loading mode of the die casting mold cavity and type of the melt flowing through the gating channels
The development of melt the melt jet melt formation was observed in the in During simulation, the development of jetwas formation wasinobserved the development of the jet the formation observed the mold shaping cavity
The presented paper analyzed the problem of the gating system in the case of a particular die-cast part
Summary
Die casting is a casting technology where molten metal is fed out of a mold loading cavity under high pressure and at high speed to a shaping cavity of a permanent mold. There it solidifies and the final cast is produced. The high flowing speed of the melt causes a rather short period of the mold cavity loading, which equals units and tenths of milliseconds. The final result in designing and structuring the gating systems for the casts produced by die casting technology is a cast showing adequate mechanical and qualitative properties. The correct structure of the gating systems can shorten the casting cycle duration, reduce the rejection rate, and positively influence the cast macrostructure that directly affects mechanical properties
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