scholarly journals The Influence of Returnable Material on Internal Homogeneity of the High-Pressure Die-Cast AlSi9Cu3(Fe) Alloy

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1084
Author(s):  
Marek Matejka ◽  
Dana Bolibruchová ◽  
Radka Podprocká
Keyword(s):  
High Pressure ◽  
Material Content ◽  
High Productivity ◽  
Die Cast ◽  
Low Weight ◽  
Key Factor ◽  
Eutectic Si ◽  
Internal Homogeneity ◽  
The One ◽  
Pressure Die Casting

Nowadays, high-pressure die-casting technology is an integral part of industrial production. High productivity, reduced machining requirements together with the low weight and advantageous properties of aluminium alloys form an ideal combination for the production of numerous components for various industries. The experimental part of the presented article focuses on the analysis of the change in the ratio of returnable material and commercial-purity alloy in a batch depending on the internal homogeneity of castings (microstructure, porosity and microhardness) from AlSi9Cu3(Fe) alloy. The use of returnable material in the batch is a key factor in achieving the maximum use of aluminium melt, which increases the economic efficiency of production and, last but not least, has a more favorable impact on the environment. Structural analysis showed that the increase in returnable material in the batch was visibly manifested in a change in the morphology of the eutectic Si. A negative change in the morphology of the eutectic Si particles was observed after increasing the returnable material content in the batch to 75%. The evaluation of porosity at control cuts showed the influence of the increase of returnable material in the batch, where the worst results were achieved by the alloy with 90% but also the one with 55% returnable material content in the batch.

Microstructure and Mechanical Properties of Low Pressure Die Cast AM50 Magnesium Alloy

2007 ◽  
Vol 546-549 ◽  
pp. 167-170 ◽  
Author(s):  
Li Ming Peng ◽  
Peng Huai Fu ◽  
Hai Yan Jiang ◽  
Chun Quan Zhai
Keyword(s):  
Mechanical Properties ◽  
High Pressure ◽  
Die Casting ◽  
Low Pressure ◽  
Microstructure And Mechanical Properties ◽  
Heat Treated ◽  
Die Cast ◽  
Second Phases ◽  
Am50 Alloy ◽  
Pressure Die Casting

Compact AM50 alloy components were cast by Low Pressure Die Casting (LPDC) process. The microstructure and mechanical properties of cast components were investigated under as-cast and heat treated states. It was found that the microstructure of LPDC AM50 is composed of α-Mg and second phases - Mg17Al12 and Al8Mn5. Compared with Gravity die casting, LPDC AM50 alloy had much coarser grains and higher density, with smaller sizes and less content of second phases. The density of AM50 alloy by LPDC process was ρ=1.7836g/cm3, with increase of 0.45% based on Gravity die casting and much more increase compared with high pressure die casting. The as-cast mechanical properties by LPDC process were: σ0.2=57.8Mpa, σb=192.3Mpa, δ=8.7%. These of Gravity die casting were: σ0.2=53Mpa, σb=173.4Mpa, δ=8.1%. UTS in LPDC increased about 20MPa, with better YTS and Elongation. Compared with that of high pressure die cast AM50, the YTS of LPDC was much lower, with comparable UTS and Elongation. The mechanical properties of the heat treated AM50 alloy were still in the same level of as-cast state. AM50 alloy by LPDC process is not necessary subjected to tempering treatment.

scholarly journals Assessment of Mechanisms for Particle Migration in Semi-Solid High Pressure Die Cast Aluminium-Silicon Alloys

2020 ◽  
Vol 4 (2) ◽  
pp. 51
Author(s):  
Madeleine Law ◽  
Christopher Neil Hulme-Smith ◽  
Taishi Matsushita ◽  
Pär G. Jönsson
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Particle Migration ◽  
Silicon Alloys ◽  
High Pressure Die Casting ◽  
Die Cast ◽  
Semi Solid ◽  
Pressure Die Casting ◽  
Saffman Lift Force ◽  
Externally Solidified Crystals

In semi-solid metal high pressure die casting and in conventional high pressure die casting, it is common to find a defect band just below the surface of the component. The formation of these bands is not fully understood. However, there are several theories as how they occur, and it has been suggested that segregation is caused by the migration of aluminium-rich externally solidified crystals. In the present work the formation of these bands is investigated theoretically by reviewing suitable potential mechanisms for the migration of such crystals. Two mechanisms are identified as the most probable: Saffman lift force and the Mukai-Lin-Laplace effect. However, it was not possible to identify which of these two mechanisms acted in the case studies. Further testing is required to identify the mechanism that is causing the migration of the aluminium globules and suitable tests are proposed.

scholarly journals Microstructure and Wear of (CrN/CrAlN)/(CrAlN/VN) and (CrN/TiAlN)/(TiAlN/VN) Coatings for Molds Used in High Pressure Casting of Aluminum

Coatings ◽  
2020 ◽  
Vol 10 (3) ◽  
pp. 261
Author(s):  
Aneta Wilczek ◽  
Jerzy Morgiel ◽  
Łukasz Rogal ◽  
Wojciech Maziarz ◽  
Jerzy Smolik
Keyword(s):  
High Pressure ◽  
Repeated Loading ◽  
Pressure Casting ◽  
Wear Resistant ◽  
X Ray ◽  
Transmission Electron ◽  
The One ◽  
Pressure Die Casting ◽  
Multilayer Stacks ◽  
Arc Deposition

Molds made of tool steels used in aluminum high-pressure die casting should routinely withstand tens of thousands of injection cycles, but repeated loading and temperature spikes result in their frequent premature wear. Extending their lifetime could be sought by nitriding or application of coatings of even higher hardness or both. Therefore, in the present experiment the arc-deposited Cr/(CrN)/nx(CrN/CrAlN)/mx(CrAlN/VN) or Cr/(CrN)/nx(CrN/TiAlN)/mx(TiAlN/VN) nano-multilayer stacks were deposited on glow discharge nitrided X40CrMoV5.1 steel. The scanning and transmission electron microscopy backed by Energy Dispersive X-ray Spectroscopy measurements of local chemical composition helped to confirm that the coatings are built of nanolayers of respective nitrides of period less than 10 nm. They also showed that droplets being characteristic for arc deposition method were enriched either in chromium, aluminum or vanadium but not in titanium. Both coatings presented comparable hardness of ~25 GPa, but the one covered with TiAlN/VN was roughly twice as wear resistant as the CrAlN/VN. Simultaneously, they were ~200 and ~100 more wear resistant than X40CrMoV5.1reference steel.

scholarly journals The Effect of Squeeze Pin Dimension and Operational Parameters on Material Homogenity of Aluminium High Pressure Die Cast Parts

2019 ◽  
Vol 16 (2) ◽  
pp. 7-12
Author(s):  
Ferencz Peti ◽  
Gabriela Strnad
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Secondary Effects ◽  
Operational Parameters ◽  
Casting Technology ◽  
Cast Aluminium ◽  
Die Cast ◽  
Primary And Secondary Effects ◽  
Pressure Die Casting ◽  
Cast Parts

Abstract The present paper is an experimental study on the squeeze pin effect on the high pressure die cast aluminium parts, as a way of improvement of material homogenity on various and big wall thickness castings. Squeeze is used in high pressure die casting technology for optimizing homogenity of big wall thicknesses of die cast parts working as structural, mechanical and hydraulic components, made of different aluminium alloys such AlSi alloys. The objective of this research is to highlight the primary and secondary effects of squeezing on the structural homogenity of high pressure die cast aluminium parts, as well as the dependence of the effects on the squeeze pin dimensions and the operating parameters.

The Heat Treatment of Rheo-High Pressure Die Cast Al-Cu-Mg-Ag Alloy 2139

2012 ◽  
Vol 192-193 ◽  
pp. 173-178 ◽  
Author(s):  
Heinrich Möller ◽  
Gonasagren Govender
Keyword(s):  
High Pressure ◽  
Tensile Properties ◽  
Artificial Aging ◽  
Die Casting ◽  
Solution Treatment ◽  
High Strength ◽  
Incipient Melting ◽  
Scanning Calorimetry ◽  
Die Cast ◽  
Pressure Die Casting

High strength wrought Al-Cu-Mg-Ag alloy 2139 was successfully processed using the CSIR rheocasting system and cast into plates using high pressure die casting. Differential scanning calorimetry was used to determine suitable homogenization/solution treatment temperatures. A two-step homogenization/solution treatment of 490oC for 24 h, followed by 520oC for 2 h does not cause any incipient melting. Artificial aging of the R-HPDC 2139 plates at 160oC for 24 h results in tensile properties similar to those reported for thixoformed casting alloy 201-T6. The minimum military specifications for wrought 2139-T8 are exceeded in terms of strength, with slightly lower ductility being obtained. Artificial aging at 153oC for 20 h results in tensile properties that exceed all the minimum military specifications for wrought 2139-T8.

scholarly journals Evaluation of Corrosion Behavior on Crept AlSi10MnMg (AA365) Alloy Produced by High-Pressure Die-Casting (HPDC)

2021 ◽  
Vol 11 (13) ◽  
pp. 6227
Author(s):  
Seonghwan Park ◽  
Cheolmin Ahn ◽  
Eunkyung Lee
Keyword(s):  
High Pressure ◽  
Intermetallic Compounds ◽  
Corrosion Behavior ◽  
Current Density ◽  
Corrosion Current Density ◽  
Galvanic Corrosion ◽  
Corrosion Current ◽  
Die Cast ◽  
Corrosive Environments ◽  
Pressure Die Casting

High-pressure die-cast AlSi10MnMg (AA365) alloys have been used as a material for automotive components exposed to high temperature and corrosive environments. This work determines the correlation of corrosion resistance with the intermetallic compounds and micro-voids of crept AA365 alloys under temperatures ranging from 373 K to 573 K with various applied stresses. The results showed that crept AA365 alloy at 473 K possessed a large amount of the intermetallic phases, compared with crept AA365 alloys at 373 K and 573 K due to the non-equilibrium solute atoms in Al matrix. By contrast, crept AA365 alloy at 573 K contained the lowest number of intermetallic precipitates owing to the remelting of the phases. With regard to the corrosion behavior, the corrosion potentials showed −687.0, −684.0, and −673.0 mVSCE of crept AA365 alloys at 373 K, 473 K, and 573 K, respectively, which means the corrosion occurred slowly on the crept AA365 alloy at 573 K, rather than at 373 K, 473 K. The value of the corrosion current density (Icorr) in the crept HPDC AA365 alloy at 473 K has the highest corrosion current density of 13.3 × 10−6 Acm−2, compared with others. It can be inferred that the high amount of intermetallic compounds gave rise to severe corrosion and led to the harmful micro-galvanic corrosion of crept AA365 alloy, rather than the micro-voids.

Segregation Characteristics of Rheo-High Pressure Die Cast Al-Alloy 2139 Plates

2015 ◽  
Vol 828-829 ◽  
pp. 100-105 ◽  
Author(s):  
Carlien Taute ◽  
Heinrich Möller
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Hot Tearing ◽  
Three Dimensions ◽  
Age Hardening ◽  
Al Alloy ◽  
Die Cast ◽  
Near Net Shape ◽  
Net Shape Forming ◽  
Pressure Die Casting

Al-Cu-Mg-Ag alloy 2139 is a wrought alloy that is heat-treatable and used in aerospace constructions. This is mainly due to the addition of silver in the alloy. Hot-tearing is a problem for casting wrought alloys with conventional liquid casting techniques. The risk is reduced by using rheo-high pressure die casting (R-HPDC) to allow the alloy to be used for near-net shape forming of components. This study investigates the segregation characteristics of R-HPDC alloy 2139. The effects of segregation on the age-hardening response as well as the tensile properties are studied. The chemical composition differences across the casting were found to aid in correlation of results. It is found that segregation occurs in three dimensions, namely from the surface to the centre of the casting, as well as across the width and length of the casting.

Influence of Wall Stocks on Mechanical Properties of HPDC AZ91

2019 ◽  
Vol 793 ◽  
pp. 41-45 ◽  
Author(s):  
Zi Xi Sun ◽  
Lu Yang Ren ◽  
Xin Yu Geng ◽  
Li Fang ◽  
Xing Yuan Wei ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
High Pressure ◽  
Dendritic Structure ◽  
Casting Process ◽  
Thick Wall ◽  
Air Entrapment ◽  
Die Cast ◽  
Engineering Requirement ◽  
Die Casting Process ◽  
Pressure Die Casting

AZ91, as one the most popular magnesium alloys is widely employed for various engineering applications in the automotive industry. They are primarily made from high pressure die cast processes (HPDC) with different wall stocks, which affect their engineering performance. Understanding the effect of thick wall stocks on mechanical behaviors of HPDC AZ91 is crucial for proper design of lightweight components to meet desired engineering requirement. In this research, a conventional high pressure die casting process was utilized to prepare rectangular specimen of AZ91 with wall thicknesses of 10 mm, 6 mm and 2 mm. Tensile testing, porosity measurement and microstructure analyses were carried out on prepared specimens at room temperature. The mechanical testing evaluation reveals that, as the wall stocks of AZ91 deceases, their tensile properties including yield strength (YS), ultimate tensile strength (UTS) and elongation (ef) increase. The porosity content caused by air entrapment and the dendritic structure due cooling mechanisms should be responsible for the resultant mechanical properties.

Microstructure and Mechanical Properties of a New Secondary AlSi10MnMg(Fe) Alloy for Ductile High Pressure Die Casting Parts for the Automotive Industry

2016 ◽  
Vol 710 ◽  
pp. 244-249
Author(s):  
Andrea Niklas ◽  
Asier Baquedano ◽  
Sergio Orden ◽  
Eulalia Noguès ◽  
Manel Da Silva ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
High Pressure ◽  
Automotive Industry ◽  
Chinese Script ◽  
Iron Compounds ◽  
Treatment Conditions ◽  
Mn Content ◽  
The One ◽  
Die Castings ◽  
Pressure Die Casting

Primary AlSi10MnMg alloy is the most widely used alloy for manufacturing of vacuum assisted high pressure die castings (VPDC) with high ductility requirements. In this alloy, die soldering is avoided by a high Mn level (0.5 - 0.6 wt. %) while Fe is kept low (< 0.25 wt. %). Such combination guarantees that the Al-Fe-Mn-Si intermetallic compounds are of the α-iron rich polyhedral or Chinese script type, which is less harmful to the ductility. However, secondary alloys are cheaper and their production requires less energy than the one of primary alloys. The higher amount of Fe, a common impurity in secondary alloys, reduces ductility but also die soldering and thus manufacturing costs. Microadditions based on Mn are known to be very effective in transforming the harmful needle/platelet shaped β-compounds into α-iron compounds with a less harmful morphology. In this work a secondary alloy with 0.60 wt. % Fe and different Mn microadditions has been cast in test parts with different wall thicknesses using VPDC technology. The Mn content of the new alloy has been optimized. Mechanical properties of the optimised alloy have been determined in different heat treatment conditions and been compared to the corresponding AlSi10MnMg primary alloy. Mechanical properties similar to those of the primary alloy have been achieved.

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