Abstract
Using vacuum die casting, 0.8 mm-thick plates in complicated shapes are manufactured with the highly castable aluminum alloy Silafont-36 (AlSi9MgMn). The sizes and shapes of the cavities, made of thin plates, feature four different mazes. To investigate formability and mechanical properties by shot condition, a total of six parameters (melt temperatures of 730 °C and 710 °C; plunger speeds of 3.0 m/s and 2.5 m/s; vacuum pressure of 250 mbar and no vacuum) are varied in experiments, and corresponding simulations are performed. Simulation results obtained through MAGMA software show similar tendencies to those of the experiments. When the melt pouring temperature is set to 730 °C rather than 710 °C, formability and mechanical properties are superior, and when the plunger speed is set to 3.0 m/s rather than to 2.5 m/s, a fine, even structure is obtained with better mechanical properties. The non-vacuumed sample is half unfilled. The tensile strength and elongation of the sample fabricated under a melt temperature of 730 °C, plunger speed of 3.0 m/s, and vacuum pressure of 250 mbar are 265 MPa and 8.5%, respectively.
Highlights
Many industries, including the automobile, aircraft, and electronics sectors, have actively researched replacing ferrous alloys with light alloy materials, such as aluminum and magnesium.Replacing a ferrous alloy with a light alloy degrades mechanical properties and increases costs, which are large problems in these industries
We examined the effects of melt temperature, plunger speed, and vacuum pressure on formability and mechanical properties
Using vacuum die casting with a Silafont-36 alloy, we fabricated a thin plate into samples with complex shapes containing four mazes
Summary
Many industries, including the automobile, aircraft, and electronics sectors, have actively researched replacing ferrous alloys with light alloy materials, such as aluminum and magnesium. It is necessary to analyze the behavior of melt when it is poured into a mold and fills the cavity, and to predict regions in which the flow of the melt is not smooth or unstable and casting defects occur. For this process, filling and solidification analyses need to be conducted by using computer-aided engineering (CAE). We propose a method for manufacturing a thin aluminum plate with a complicated shape by using vacuum die-casting. A 660-ton cold chamber die-casting machine was used and the melt material was a Silafont-36 (AlSi9MgMn) alloy
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