Abstract
The porosity inside die castings influences the pressure resistance of the products. Especially, elongated porosity tends to become the air leakage path. We have investigated the post compression process of ADC12 aluminum alloy die castings to intercept the air leakage path through the porosity by closing some parts of elongated porosity. The closing behavior of porosity was affected by the shape and the distribution of porosity. In this study, two-dimensional image-based finite element analysis was performed to find the optimum compression condition considering the actual shape and distribution of porosity inside die castings. The finite element mesh was generated from X-ray CT images of the ADC12 aluminum alloy die casting specimen. The closing behavior of porosity obtained from experimental result and finite element analysis result is well conformed. We proved that the two-dimensional image-based finite element method is valid to estimate the optimum condition of the post compression process. We investigated the minimum compression rate to intercept the air leakage path both at room temperature and at high temperature by using the same two-dimensional image-based finite element mesh. In the manufacturing field, the temperature condition is also important. Especially at high temperature, the bonding of porosity after closing is expected.
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