Reducing Non Value Adding Aluminium Alloy in Production of Parts by High Pressure Die Casting Using High Temperature Die Manufacturing Material

Abstract

The difficulties and issues associated with the economics of the process and die life in casting aluminium alloys, as experienced by the high pressure die casting industry, were reasons behind undertaking this research project. The use of a tungsten alloy able to withstand high temperature process conditions without the welding problems experienced by standard die construction materials, such as H13, was examined in an extensive series of casting trials. The importance of operating dies at elevated temperatures to minimize heat checking has been demonstrated previously, both through theoretical thermal modelling and experimentation. This paper describes both aspects of die life extension and possibilities to reduce the amount of alloy material used in the cast part feed system, including overflows. CSIR intends using the results of this research for further development and application of high temperature die construction materials in high pressure die casting processes of light metal alloys.