Abstract
The aim of this study was to determine the correlation between the size and the distribution of microstructural constituents and their cooling rate, as well as the correlation between the mechanical properties and the cooling rate of AlSi9Cu3 aluminum alloy when cast in high-pressure die casting (HPDC) conditions. In other words, the ultimate goal of the research was to determine the mechanical properties for a casting at different cooling rates. Castings with different wall thicknesses were chosen, and different cooling rates were assumed for each one. Castings from industrial technological practice were systematically chosen, and probes were extracted from those castings for the characterization of their mechanical properties. Special non-standard cylinders were created on which compressive tests were carried out. The uniqueness of this research lies in the fact that the diameters of the designed cylinders were in direct correlation to the actual wall thickness of the castings. This is important because the solidification of metal in the die cavity is complex, in that the cooling rates are higher on the surface of the casting than in the center. Local in-casting cooling rates were determined using numerical simulations. It was discovered that with increasing cooling rates from 60 K/s to 125 K/s the values for strength at 5% deformation increased on average from 261 MPa to 335 MPa.
Highlights
Aluminum castings were the first important market soon after the commercialization of the electrolytic extraction of aluminum according to the Hall–Héroult method
The invention of casting in permanent molds and pressurized filling as alternatives to sand casting have promoted the development of new alloys which have had to be suitable for application and for the development process itself [1]
High-pressure die casting (HPDC) is the process of filling a cavity at a high speed and pressure in a preheated, usually steel mold or tool, which enables the production of thin-walled castings and short production cycles
Summary
Aluminum castings were the first important market soon after the commercialization of the electrolytic extraction of aluminum according to the Hall–Héroult method. Aluminum castings became economically suitable for applications in industry after the gradual decrease in the price of aluminum at the end of the 19th century. The characterization of their physical and mechanical properties with performance testing were crucial factors for the constant development of new alloys. The invention of casting in permanent molds and pressurized filling as alternatives to sand casting have promoted the development of new alloys which have had to be suitable for application and for the development process itself [1]. High-pressure die casting (HPDC) is the process of filling a cavity at a high speed and pressure in a preheated, usually steel (hot working tool steel) mold or tool, which enables the production of thin-walled castings and short production cycles. The arrival of aluminum alloy AlSi9Cu3 in the industry— marked as 226 D according to German
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