High Pressure Die Casting Research Articles

Inhomogeneous Skin Formation and Its Effect on the Tensile Behavior of a High Pressure Die Cast Recycled Secondary AlSi10MnMg(Fe) Alloy

AbstractThe current study investigated the microstructure evolution, mechanical properties, and fracture behavior of a high pressure die cast (HPDC) novel secondary alloy. The as-cast microstructure comprised (i) Primary α-Al, (ii) α-Al15(FeMn)3Si2 intermetallics, and (iii) Al–Si eutectics. The microstructure starting from the surface through the depth of the HPDC casting consisted of (i) fine-grained skin at surface, (ii) increased Al–Si eutectics at intermediate location, and (iii) coarse α-Al dendrites at center. Accordingly, the hardness increased from skin to the intermediate section and then decreased toward the center of the casting. The formation of skin layer was highly discontinuous, which was attributed to the complicated fluid flow pattern inside the die cavity. The skin layer indicated to slightly improve the strength of the HPDC alloy; however, it restricted the ductility of the material with a large variation. Such ductility behavior resulted from a fracture mechanism triggered by the inhomogeneous skin because of its poor bonding with the adjacent matrix. Even though the secondary alloy contained casting defects and α-Al15(FeMn)3Si2 intermetallics that are known to be driving factors for the fracture in such materials, the effects from the inhomogeneous skin turned out to be predominant in the current study.

Thermal Conductivity of AlSi10MnMg Alloy in Relation to Casting Technology and Heat Treatment Method

Nowadays, with the development of electromobility, the requirements not only for the mechanical properties but also for the thermal conductivity of castings are increasing. This paper investigates the influence of casting and heat treatment technology on the thermal diffusivity and thermal conductivity of an AlSi10MnMg alloy. The thermal diffusivity was monitored as a function of temperature in the range of 50–300 °C for the material cast by high-pressure die casting (HPDC) and also by gravity sand casting (GSC) and gravity die casting (GDC). This study also investigated the effect of the T5 heat treatment temperature (artificial ageing without prior solution treatment—HT200, HT300, and HT400) on the thermal conductivity of the material cast by different technologies. Experiments confirmed that the thermal diffusivity or thermal conductivity of the alloy depends on the casting technology. The slower the cooling rate of the casting, the higher the thermal conductivity value. For the alloy in the as-cast condition, the thermal conductivity at 50 °C is in the range of about 125 to 138 [W·m−1·K−1]. Regardless of the casting method, the thermal conductivity tends to increase with temperature (50–300 °C). Furthermore, a positive effect of heat treatment without prior solution treatment (HT200, HT300, and HT400) on the thermal conductivity was demonstrated. Regardless of the casting method of the samples, the thermal conductivity also increases with increasing heat treatment temperature. The results further showed that when artificial ageing is performed in industrial practice on castings to increase mechanical properties in the temperature range of 160–230 °C, this heat treatment has a positive effect on thermal conductivity.

The Influence of Surface Segregation on the Anodizing of AlSi11Cu2(Fe) Diecastings

A positive segregation is usually formed on the casting surfaces produced by high-pressure die casting (HPDC). In diecast Al-Si-Cu alloy components, this segregation shows a higher content of Si compared to the nominal composition of the alloy and it drastically affects the anodizing response of the casting surface. In the present work, HPDC components were produced by AlSi11Cu2(Fe) alloy, grit-blasted, and then anodized in a sulfuric acid electrolyte at the temperature of -4.5°C. Before the anodizing process, some regions of the casting were also milled, in order to completely remove the surface segregation. Microstructural investigations were carried out on grit-blasted and milled surfaces to characterize the initial substrates before anodizing, and to study their effect on the growth of the anodic layer. Scratch and wear tests were also performed to investigate the surface mechanical properties after anodizing. The results show that the surface segregation and the rough surface present on grit-blasted substrate leads to the formation of a thin and homogeneous anodic layer. On the contrary, a thicker and scalloped oxide film is formed on the milled surfaces. After anodizing, grit-blasted surfaces show lower wear and scratch resistance than milled substrates. The presence of surface segregation prevents the thickening of the anodic layer, negatively affecting the surface wear resistance due to the reduced oxide thickness.

The Evolution of Dilatant Shear Bands in High-Pressure Die Casting for Al-Si Alloys

Bands of interdendritic porosity and positive macrosegregation are commonly observed in pressure die castings, with previous studies demonstrating their close relation to dilatant shear bands in granular materials. Despite recent technological developments, the micromechanism governing dilatancy in the high-pressure die casting (HPDC) process for alloys between liquid and solid temperature regions is still not fully understood. To investigate the influence of fluid flow and the size of externally solidified crystals (ESCs) on the evolution of dilatant shear bands in HPDC, various filling velocities were trialled to produce HPDC samples of Al8SiMnMg alloys. This study demonstrates that crystal fragmentation is accompanied by a decrease in dilatational concentration, producing an indistinct shear band. Once crystal fragmentation stagnates, the enhanced deformation rate associated with a further increase in filling velocity (from 2.2 ms−1 to 4.6 ms−1) localizes dilatancy into a highly concentrated shear band. The optimal piston velocity is 3.6 ms−1, under which the average ESC size reaches the minimum, and the average yield stress and overall product of strength and elongation reach the maximum values of 144.6 MPa and 3.664 GPa%, respectively. By adopting the concept of force chain buckling in granular media, the evolution of dilatant shear bands in equiaxed solidifying alloys can be adequately explained based on further verification with DEM-type modeling in OpenFOAM. Three mechanisms for ESC-enhanced dilation are presented, elucidating previous reports relating the presence of ESCs to the subsequent shear band characteristics. By applying the physics of granular materials to equiaxed solidifying alloys, unique opportunities are presented for process optimization and microstructural modeling in HPDC.

Friction stir processing: A thermomechanical processing tool for high pressure die cast Al-alloys for vehicle light-weighting

This study uses friction stir processing (FSP) for thermomechanical processing of high-pressure die-casting (HPDC) to modify microstructure and improve mechanical properties. FSP is carried out on two different HPDC aluminum alloys: (a) general-purpose, high-iron, HPDC A380 alloy and (b) premium quality, low-iron HPDC Aural-5 alloy in thin wall, flat plate geometry. Subsequent mechanical testing shows ∼30 % and ∼65 % enhancement in yield strength and tensile ductility. In addition, FSP leads to ∼10 times improvement in fatigue life for A380 alloy and ∼70 % improvement in fracture toughness for Aural-5 alloy. These findings emphasize the capability of FSP to modify the microstructure of HPDC Al-alloys-based structural components so that they can demonstrate a good combination of strength, ductility, fracture toughness, and high fatigue properties for long-term durability and reliability.

Data Models for Casting Processes – Performances, Validations and Challenges

Abstract Data-driven models with their associated data learning and training schemes can be utilised for the light metal casting processes. This paper presents the basis of data model building processes along with data training and learning exercises for vertical direct chill casting and high pressure die casting (HPDC) applications. The concepts of efficient database building, data translations and sampling, as well as real-time model building and validations are briefly discussed. Rigorous performance studies were additionally carried out for two real-world case studies. Different combinations of data solvers and interpolators are adapted for the model building techniques, while machine learning schemes are used for data trainings.

Wear properties of a new Al80Mg10Si5Cu5 multicomponent alloy

The present study investigates the tribological properties of a newly developed multicomponent aluminium weight-light multicomponent alloy for wear based on the Al80Mg10Si5Cu5 system for lightweight automotive applications, especially back drum discs. The samples were manufactured by High-Pressure Die Casting (HPDC) employing cast alloy returns and secondary aluminium ingots and were tested at room temperature (RT) and 200 °C. It has been observed that the Al80Mg10Si5Cu5 alloy offers a higher hardness and wear resistance at RT and especially at 200 °C compared with the AlSi9Cu3 reference alloy (x10 times reduction in wear rate). The impact of maintaining the external surface layer (skin) of HPDC cast parts has been studied for the ball-on disc test, showing improved tribological properties and the possibility of avoiding the machining of contact surfaces. The as-cast Al80Mg10Si5Cu alloy with the surface layer showed a wear rate coefficient of 5 × 10−4 mm3/N.m2 at RT, a 50 % lower than that of the sample without skin. Solution heat-treated samples (72 h at 440 °C, water quenching at 75 °C, and natural aging) with the surface layer showed a wear rate coefficient of 11 × 10−4 mm3/N.m2, approximately 20 % lower than the sample without a surface layer. The wear rate of AlSi9Cu3 alloy decreased by more than 50 % in the samples without skin at RT. At 200 °C, wear rate coefficients were lower in the samples with the surface layer.

Development of Heat Treatments for Structural Parts in Aluminium Alloys Produced by High-Pressure Die Casting (HPDC)

In this work, we intended to study the effect of heat treatments (T5 and flash T6) on blistering, mechanical properties and microstructure for different parts produced by vacuum-assisted HPDC. These parts were produced with primary and secondary aluminium alloys (AlSi10MnMg alloy and AlSi10Mg(Fe) alloy, respectively). The parts presented blisters for all combinations of temperature (between 360 °C and 520 °C) and stage times (15 and 30 min) of solution heat treatments. However, when subjected to the T5 heat treatment, blisters were no longer visible. With this heat treatment, there was an increase in yield strength of 64% for both aluminium alloys and an increase in UTS of 31% in AlSi10Mg(Fe) alloy and of 24% in AlSi10MnMg alloy, when compared to the mechanical properties in the as-cast state. However, there was a decrease in ductility. The AlSi10Mg(Fe) alloy presented a lot of contaminations (especially iron), which impaired the mechanical properties compared to the primary aluminium alloy, AlSi10MnMg.

The aging-hardening behavior of short-time in high pressure die casting AlSi9MgMnZn alloy

Short-time aging is an effective industrial technique for enhancing the mechanical properties of high pressure die cast (HPDC) aluminum alloy components. However, the evolution of precipitation behavior during short-time aging of HPDC alloys remains unclear. In this study, the short-time aging behavior of HPDC AlSi9MgMnZn alloy was investigated. The results show that the AlSi9MgMnZn alloy exhibits effective aging-hardening, with an increment in hardness of approximately 30 HV through the optimal short-time aging treatment (aged at 180 °C for 120 minutes). Higher aging temperatures led to reduced peak hardness and rapid over-aging above 220 °C. The microstructure observation indicates that the peak short-time aging promotes the simultaneous precipitation of β″ precipitates, GP zones and nano Si phases. The contribution of different strengthening mechanisms to hardness was estimated, implying that the coexistence of β″ precipitates and GP zones can provide a positive contribution to aging-hardening during short-time aging. Moreover, as the aging temperature increases, the appearance of β′ precipitates reduces the strengthening effect, leading to a decrease in hardness.

Recurrent neural networks as virtual cavity pressure and temperature sensors in high-pressure die casting

High-pressure die casting (HPDC) is a permanent mold-based production technology that facilitates the casting of near net shape components from nonferrous alloys. The pressure and temperature conditions within the cavity impact the cast product quality during and after the conclusion of the die filling process. Die surface cavity sensors can deliver information describing the conditions at the die-casting interface. They are associated with high costs and limited service lifetimes below the achievable total cycle count of the die inserts and therefore ill-suited for industrial use cases. In this work, the suitability of long short-term memory (LSTM) recurrent neural networks (RNN) for substituting physical cavity temperature and pressure sensors virtually after the production ramp-up or at the end of the sensor service life is investigated. Training LSTMs with data of 233 casting cycles with different process parameters provides networks which are then applied to 99 further cycles. The prediction accuracy is investigated for different time interval lengths in the solidification and cooling phase. For longer time intervals, the cavity pressure prediction deteriorates, potentially due to a highly individual and hardly ascertainable buildup of casting distortion and internal stresses. Overall, however, the accuracy of the developed LSTMs is excellent for the cavity temperatures and good for the cavity pressures.

Comprehensive regulation of mechanical properties and thermal conductivity of Al-Si-Fe alloys through the mixed-additive (Sr and TiB2) strategy

It is of both scientific and technical significance to adjust the balance between the thermal conductivity and mechanical performance of Al-Si alloys. In this work, we proposed a strategy of using mixed-additive to perform such tuning. A permanent mold casting (PMC) was used to optimize the as-cast properties based on the orthogonal combination of Sr and TiB2. It is anticipated that the addition of Sr addition can modify the eutectic Si, while the addition of TiB2 can refine the primary α-Al dendrites, with uncertainty of its effects on the modification efficiency of Sr. The results showed that addition of TiB2 does not impair the modification efficiency of Sr. The optimized composition contained 200 ppm Sr and 300 ppm Ti. Casting specimens were then prepared using high-pressure die casting (HPDC) process. The results demonstrated that significant reduction in the size of β-AlFeSi, eutectic Si, and α-Al grains can be achieved by HPDC process. As a result, the tensile properties have been improved. The natural effects of HPDC process on the alloy, however, such as microstructure refinement and variation in porosity, leading to deduction in the thermal conductivity to 148.5 W/(m·K). This value still exceeds conventional alloys nevertheless.

Friction stir processing on a strontium modified, thin-wall, vacuum-assisted high-pressure die-cast Aural-5 alloy to improve tensile and fatigue performance

This study explores the application of friction stir processing (FSP) to enhance the material properties of Sr-modified Aural-5 alloy, with a focus on improved tensile and fatigue properties. Aural-5 is a well-known vacuum-assisted high-pressure die-cast (HPDC) Al–Si7–Mg alloy used in the automotive industry to reduce vehicle weight, enhance fuel efficiency, and lower carbon emissions. This alloy modifies its material chemistry with Sr for fine fibrous networks of eutectic silicon and manganese (Mn) to reduce die soldering. It has significantly less iron (Fe) content resulting in the elimination of detrimental needle-shaped Fe-bearing β-phase intermetallic and improving ductility. The initial microstructure of as-received HPDC Aural-5 exhibits shrinkage porosity in the middle section, a dendritic microstructure with fibrous Al–Si eutectic colonies, a shear-band structure beneath the die-wall, large dendritic externally solidified crystals (ESCs), needle-shaped Mg2Si phase and significant second-phase particulates. Some of those microstructural features, such as porosity, ESCs, needle-shaped Mg2Si phase, and large second-phase particles, serve as initiation sites for cracks under mechanical loading, resulting in adverse effects on tensile properties, particularly ductility. FSP effectively transforms the microstructure into a wrought configuration with uniform particle distribution by eliminating porosity and disintegrating dendrites, eutectic colonies, ESCs, second-phase particles, and shear-band structures. FSP-driven microstructure modification enhances yield strength and tensile ductility by ∼30 % and ∼35 %, respectively. The fatigue life of the material in a bending mode configuration (stress ratio R = 0.1) after FSP exhibits enhancements ranging from 2.0 to 3.9 times that of the original HPDC Aural-5 alloy, depending on the applied stress level.

Correlation of Electron Configuration, Electronegativity, and Ionization Energy of Strontium on the Modification of Eutectic Si in High-Pressure Die Cast A380 Al–Si Alloys

Correlation of Electron Configuration, Electronegativity, and Ionization Energy of Strontium on the Modification of Eutectic Si in High-Pressure Die Cast A380 Al–Si Alloys

Semi-solid rheo-diecast Mg-xGd-3Y–1Zn-0.4Zr (wt%) alloys and their comparison with conventional HPDC alloys

This work systematically investigated the microstructure and mechanical properties of Mg-xGd-3Y–1Zn-0.4Zr (wt%) alloys prepared via rheo-diecasting (RDC) in comparison to those of conventional high pressure die casting (HPDC) alloys, and revealed their differences in microstructure, casting defects, and mechanical properties. The microstructure of the as-cast RDC Mg-xGd-3Y–1Zn-0.4Zr (wt%) alloys is primarily composed of α-Mg and Mg3(Gd,Y,Zn) eutectic phases. Of the four alloys studied, the GWZ831K and GWZ1431K alloys exhibit the best elongation (EL: 6.4±1.3 %) and the highest strengths (UTS: 270±9 MPa; YS: 201±5.7 MPa), respectively. The GWZ831K alloy exhibits a quasi-cleavage fracture during room-temperature tensile tests, whereas the GWZ1431K alloy demonstrates a brittle fracture. The phase composition of conventional HPDC alloys is fundamentally the same as that of RDC alloys, but their grains and eutectic phases differ in morphology and are smaller in size. Oxide films are frequently found in conventional HPDC castings, but neither oxide films nor pore defects are observed in RDC alloys. Compared to conventional HPDC alloys, RDC alloys have better elongation but lower strength. The lower strength of RDC alloys compared to HPDC alloys can be attributed to larger grains and eutectic phases, along with fewer stacking faults (SFs), resulting in limited strengthening effects of grain boundaries, eutectic second phases and SFs. In contrast, RDC alloys exhibit superior elongation compared to HPDC alloys due to the elimination of oxide films and pore defects, as well as the excellent ductility of the α-Mg matrix that can effectively coordinate deformation.

Development of Casting Product Using Reverse Engineering Technology: A Case Study

Abstract. One solution to increase domestic industry competitiveness and performance is mastering reverse engineering (RE) technology. Through mastery of this technology, the use of domestic components will increase. However, this is still an obstacle due to a weak understanding of RE technology and the availability of RE facilities. This article will examine the RE process of a casting product and optimize the product manufacturing process through simulation with casting software for the High-Pressure Die Casting (HPDC) process with a case study of a top body converter product. This research begins with product identification, development, and optimization. The next step is to determine the design and injection parameters to be simulated in the Inspire casting software and then design the HPDC mold. Through RE technology, this research has produced an optimal top body converter product with a weight 36% lighter than the initial weight, and an HPDC mold design for the optimal product has been produced.

A new high-pressure die casting Mg−Gd−Sm−Al alloy with high strength-ductility synergy

A high-pressure die casting (HPDC) Mg−5Gd−1.5Sm−0.7Al alloy was newly developed and exhibits outstanding strength-ductility synergy, with the yield strength and the tensile elongation to fracture being approximately 200 MPa and 8.5%, respectively. This alloy has two types of α-Mg grains: coarse α1-Mg ((46 ± 18) μm) and fine α2-Mg ((9.2 ± 2.3) μm) grains, and various Al-GS (GS = Gd and Sm) particles located at grain boundaries while clear solute-atom segregation near grain boundaries with limited or free intermetallic particles. Characterizations using Cs-corrected high-angle annular dark-field scanning transmission electron microscopy (HAADF-STEM) indicate the crystal structures of Al-GS phases. After aging, dense β′ precipitates and chain-shaped β’’-like structures precipitated near grain boundaries while a high density of ultrafine β’’-(Mg,Al)3Sm precipitates and Al-GS clusters formed in grain center. Relatively fine grains, Al-GS primary particles, solute-atom segregation near grain boundaries, and/or multiple precipitates contribute to the high strength of the studied alloy, while the multi-scale α-Mg grains, variety of intermetallic particles but discontinuous skeleton, and the multi-typed precipitated lead to its satisfactory ductility.

Modifying the Microstructure and Mechanical Properties of Non-Heat Treated HPDC AlSi10MnMg Foundry Alloy via Incorporation of TiB<sub>2</sub> Particles and Sc

The demand for structural lightweight in a variety of industries, particularly the automobile industry, has driven the development of heat-free die-cast aluminum alloys with excellent properties. Utilizing lightweight materials, such as Al-Si alloys has several benefits, including higher overall performance in automobiles and other industries, increased heat resistance efficiency, decreased emissions, and reduced weight. The purpose of this study is to modify the microstructure and enhance the mechanical properties of high-pressure die-casting (HPDC) AlSi10MnMg foundry alloy by incorporation of TiB2 and Sc without any heat treatment. The results showed that the HPDC process significantly refines the grain structure and AlSiMnFe intermetallic compounds, transforming the eutectic morphology from sharp to rounded, and 93% enhancement in elongation at the optimum content (0.018 wt.%) of TiB2. While the hardness of the alloy was improved by 15.7% with the addition of 0.03wt.% TiB2. TiB2 incorporation refines the grain structure and AlSiMnFe phases, while depressing externally solidified crystals (ESCs). The HPDC process refines Al3Sc phases as well as AlSiMnFe phases while increasing yield strength due to Al3Sc strengthening effects. After 0.5wt.% Sc addition in 0.018wt.% TiB2-AlSi10MnMg alloy, the YS, and EL reached the maximum of 196MPa and 9.93% respectively.

Determination of transient heat transfer by cooling channel in high-pressure die casting using inverse method

Complex shapes of aluminum castings are typically manufactured during the short cycle process known as the high-pressure die casting (HPDC). High productivity is ensured by introducing die cooling through a system of channels, die inserts or jet coolers. Die cooling can also effectively help in reducing internal porosity in cast components. Accurate simulations based on sophisticated numerical models require accurate input data such as material properties, initial and boundary conditions. Although the heat is dominantly dissipated through die cooling, indicating the importance of knowing precise thermal boundary conditions, open literature lacks a detailed information about the spatial distribution of heat transfer coefficient. This study presents an inverse method to determine accurate heat transfer coefficients of a die insert based on temperature measurements in multiple points by 0.5 mm K-type thermocouples and a subsequent solution of the two-dimensional inverse heat conduction problem. The solver was built in the open-source CFD code OpenFOAM and the free library for nonlinear optimization NLopt. The results are presented for the commonly used 10 mm die insert with a hemispherical tip and coolant flow rates ranging from 100 l/h to 200 l/h. Heat transfer coefficients reach values well above 50 kW/m2K in the hemispherical tip, which is followed by a secondary peak and then a gradual drop to values around 1 kW/m2K further downstream.

Formation mechanism of the microstructural heterogeneity in a die-cast Al-Mg-Si alloy and its effect on mechanical properties

Al-Mg-Si series alloys fabricated by high pressure die casting (HPDC) have a broad application prospect in the production of large-scale and thin-walled die-castings. However, the die-cast Al-Mg-Si series alloys usually exhibit obvious microstructural heterogeneity. This study investigated the microstructural heterogeneity of the die-cast Al-7 Mg-3Si alloy along the thickness direction, and the corresponding formation mechanism was verified. In this study, the die-cast sample can be divided into four distinct regions (R1 ∼ R4) from the surface to the center in turn according to the area fraction of the primary α-Al. Two aspects were considered to be the main reasons for the formation of microstructural heterogeneity. On the one hand, the externally solidified crystals (ESCs) preferentially formed in the shot sleeve and aggregated in the casting center. On the other hand, the cooling rates were quite different in each region, leading to different solidification behaviors. Based on the combination of the microstructural observation and calculated cooling rates, a physical model has been proposed to describe the formation mechanism of the microstructural heterogeneity. The heterogeneous microstructure of the die-cast sample resulted in the inhomogeneity of mechanical properties along the thickness direction. The R2 exhibited the highest micro-hardness than the other regions because of its highest amount of eutectics. Moreover, the casting surface with fine grains (R1) is conducive to improving the EL, whereas the center (R4) showed the lowest tensile properties due to the existence of ESCs and porosity band.

Effect of surface roughness and eutectic segregation on anodising of Al-Si-Cu alloys

To study the influence of the surface roughness and eutectic silicon segregation on the anodising of diecast Al-Si-Cu alloys, an AlSi11Cu2(Fe) alloy was high-pressure diecast and hard anodised. The microstructure and surface topography of milled and grit-blasted regions were investigated to analyse their effect on the growth of the anodic layer. The surface mechanical properties of the anodised surfaces were also studied. The results showed how high surface roughness and silicon segregation present in the grit-blasted surface hindered the thickening of the oxide layer. After anodising, the milled surface exhibited better mechanical properties than the grit-blasted one. The wear resistance was enhanced by a thicker anodic layer, while the scratch resistance was positively affected by a lower surface roughness.