Abstract
To investigate die filling from a semisolid melt, a die was designed to cast a two-part test sample with restrictions in one part and steps of different thicknesses in the other. Several defect types were observed including surface eutectic segregation, gas holes with eutectic segregation, oxide flaws, and shrinkage porosity. The effect of melt injection velocity on liquid segregation in the cast parts was investigated using macro–microstructural observation and computer simulation. Process parameters to reduce liquid segregation were obtained by computer simulation. The effect of injection speed of the plunger tip on liquid segregation was most significant after the semisolid material had filled the runner. According to experimental and simulation results, liquid segregation could be removed by controlled high plunger speed (more than 0.3m/s).
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