The Effects of Thermal and Dynamical Parameters and Vacuum Application on Porosity in High-Pressure Die Casting of A383 Al-Alloy

Abstract

High-Pressure Die Casting (HPDC) is a near-net shape manufacturing method for the non-ferrous materials casting process, and it is widely used in the automotive industry. In the HPDC method, mold (TM) and casting temperature (TC), first- (V1) and second (V2)-phase injection velocity, injection pressure (P3), mold and casting material, mold design and vacuum application are all important parameters for producing high-quality products, as they directly affect the mechanical and metallurgical properties and micro–macroporosity of the product parts. In this study, the effects of thermal (mold and casting temperature) injection parameters and dynamic (pressure, velocity and vacuum application) injection parameters on the mechanical properties and porosity of the samples were studied. In the experiments and simulations performed as part of this study, A383 was selected as the casting material and DIN 1,2344 as the hot work tool steel. The mold cavity was shaped according to the tensile test specimen. The experiments were repeated under 64 different conditions, using different dynamic and thermal parameters and vacuum application drawn in the mold cavity. The samples obtained from the experiments were subjected to tensile tests to identify their mechanical properties. A gas pycnometer was used to measure and calculate porosity rates. All the tests were simulated using FLOW-3D software proper to the experimental conditions. In conclusion, the most useful thermal parameters obtained from the experimental study were found to be 1063 K for casting temperature and 493 K for mold temperature, while the optimum dynamic parameter values were determined to be 1.7 m/s injection velocity and 10–20 MPa injection pressure for vacuum application drawn in the mold cavity.