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

Anodising of aluminium alloy components can be used for decorative purposes and to enhance the corrosion and wear resistance. In this research, four different Al-alloy series namely Al-Cu-Mg (2xx/2xxx), Al-Si-Mg (3xx), Al-Mg-Si (6xxx) and Al-Zn-Mg-Cu (7xxx) were used to produce plates by rheo-high pressure die casting (R-HPDC). Castings produced by R-HPDC suffer from a surface liquid segregation (SLS) phenomena. This surface layer is enriched with alloying elements and it is shown to have different characteristics as compared to the bulk material. The study focused on the anodisability of plates from the four series produced by R-HPDC with and without the SLS. The samples were anodised at a commercial facility. The oxide layer thickness and homogeneity were studied using optical microscopy.

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A Development of Virtual Manufacturing System for Magnesium High Pressure Die Casting Processes

Materials ◽

10.1115/imece2003-55228 ◽

2003 ◽

Author(s):

Weilong Chen

Keyword(s):

High Pressure ◽

Magnesium Alloys ◽

Die Casting ◽

Virtual Manufacturing ◽

Mold Design ◽

High Pressure Die Casting ◽

Molten Magnesium ◽

Pressure Die Casting ◽

Soft And Hardware ◽

Free Magnesium

In recent years, high-pressure die-casting magnesium components have been gaining currency worldwide because of the excellent properties that magnesium alloys can offer to meet new product requirements. With the increasing application of magnesium parts worldwide, many research and development projects have been carried out to advance HPDC technology. However, truly optimized mold design and production of defect free castings remains a challenge for die casters. For many HPDC magnesium products, especially those specified for porosity-free and high cosmetic requirement, the challenge not only comes form a lack of a deeper understanding of how molten magnesium alloys fill the mold cavity and form defects, but also from improper preliminary part design. This study proposes a virtual prototyping system that integrates several effective soft and hardware tools for both the part and mold-design engineer to evaluate part manufacturability. Also, investigated in this study are the major causes of those defects that are the predominant cause of rejection of thin walled, leak-free magnesium parts requiring highly cosmetic finishes.

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A Neural Network Based Defect Prediction Approach for Virtual High Pressure Die Casting

Journal of Physics Conference Series ◽

10.1088/1742-6596/1948/1/012019 ◽

2021 ◽

Vol 1948 (1) ◽

pp. 012019

Author(s):

Xu De-Jian ◽

Yu Yong-Peng

Keyword(s):

Neural Network ◽

High Pressure ◽

Die Casting ◽

Defect Prediction ◽

High Pressure Die Casting ◽

Pressure Die Casting ◽

Prediction Approach

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Design and optimization of gating system, modification of cooling system position and flow simulation for cold chamber high pressure die casting machine

Materials Today Proceedings ◽

10.1016/j.matpr.2020.11.346 ◽

2021 ◽

Author(s):

Amol R. Jadhav ◽

Deepak P. Hujare ◽

Pravin P. Hujare

Keyword(s):

High Pressure ◽

Cooling System ◽

Die Casting ◽

Casting Machine ◽

Flow Simulation ◽

Gating System ◽

High Pressure Die Casting ◽

Design And Optimization ◽

Cold Chamber ◽

Pressure Die Casting

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On the Use of Conformal Cooling in High-Pressure Die-Casting and Semisolid Casting

Technologies ◽

10.3390/technologies9020039 ◽

2021 ◽

Vol 9 (2) ◽

pp. 39

Author(s):

Anders E. W. Jarfors ◽

Ruslan Sevastopol ◽

Karamchedu Seshendra ◽

Qing Zhang ◽

Jacob Steggo ◽

...

Keyword(s):

High Pressure ◽

Die Casting ◽

Life Extension ◽

Conformal Cooling ◽

High Pressure Die Casting ◽

Cooling Channels ◽

Die Life ◽

Die Materials ◽

Pressure Die Casting ◽

Semisolid Casting

Today, tool life in high pressure die casting (HPDC) is of growing interest. A common agreement is that die life is primarily decided by the thermal load and temperature gradients in the die materials. Conformal cooling with the growth of additive manufacturing has raised interest as a means of extending die life. In the current paper, conformal cooling channels’ performance and effect on the thermal cycle in high-pressure die casting and rheocasting are investigated for conventional HPDC and semisolid processing. It was found that conformal cooling aids die temperature reduction, and the use of die spray may be reduced and support the die-life extension. For the die filling, the increased temperature was possibly counterproductive. Instead, it was found that the main focus for conformal cooling should be focused to manage temperature around the in-let bushing and possibly the runner system. Due to the possible higher inlet pressures for semisolid casting, particular benefits could be seen.

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