Using Micro-CT Scanning to Quantitative Characterize Porosity in High Pressure Die Castings and Semi-Solid Castings

Porosity is one of the main defects that limits the performance of castings. Porosity in aluminum castings can originate from several sources, including the volumetric shrinkage occurring during solidification, the precipitation of dissolved hydrogen, and entrapment of gasses such as air, boiling water, vaporized lubricants, etc. Traditional methods of identifying and measuring porosity in castings include 2D x-rays, sectioning and polishing, and Archimedes density measurements, but none of these provide a satisfactory quantitative estimate of the size, total volume and distribution of the pores. X-ray CT scanning is a relatively new method that generates not only a 3-dimensional view of the size and distribution of the pores, but can also provide quantitative information of the volume, surface area, size, shape and position of each pore within a casting. Micro-CT scanning is a specialized sub-category of CT scanning, which provides excellent resolution of fine porosity (a resolution limit of 4 microns in one of the case-stores presented in this paper), but it should be noted that the resolution limit in CT scanning techniques is related to sample size. This paper describes results from micro-CT scanning studies of two high pressure die castings and a semi-solid casting, and provides quantitative data on the total porosity content, and the porosity distribution. The paper will also demonstrate the capabilities of the micro-CT scanning process to provide a quantitative comparison of the porosity content in these different types of aluminum castings.

Effect of Injected Oxygen Amount on the Gas Porosity and Mechanical Properties of a Pore-Free Die-Cast Al–Si–Cu Alloy

With the rise in the demand for eco-friendly and electric vehicles, welding and heat treatment are becoming very important to meet the necessary weight reduction, complexity, and high functionality of die castings. Pore-free (PF) die casting is an effective process that enables heat treatment and welding due to low gas porosities. Indeed, this process affords castings of low gas porosity, similar to those attained by high-vacuum die casting. In this study, we compared the gas porosities of different castings fabricated by PF die casting using varied injected oxygen amounts. The castings were all subjected to T6 heat treatment and analyzed by computed tomography (CT) to compare their microstructure and mechanical properties before and after T6 heat treatment. The results revealed that with the increasing injected oxygen amount, the gas porosity of the specimens decreased while their mechanical properties increased. In particular, the gas porosity was the lowest at 1.26 L. Moreover, the 1.26 L specimen displayed the best tensile strength, yield strength, and elongation results. Finally, Weibull distribution analysis revealed that the tensile strength and elongation repeatability and reproducibility increased with increasing injected oxygen amount.

RHEINFELDEN CASTASIL-37

Rheinfelden Castasil-37 (AlSi9MnMoZr) is an aluminum-silicon-manganese-molybdenum-zirconium high pressure die casting (HPDC) alloy. It was developed by Rheinfelden Alloys GmbH for the production of large and complex high pressure die castings for automotive structural applications. This alloy is used in the as-cast condition, and exhibits good mechanical properties, especially elongation, which are superior to those of conventional aluminum-silicon alloys. This datasheet provides information on composition, physical properties, hardness, elasticity, and tensile properties as well as fatigue. It also includes information on corrosion resistance as well as casting, heat treating, and joining. Filing Code: Al-481. Producer or source: Rheinfelden Alloys GmbH & Co. KG.

Experimental and numerical investigations of oxide-related defects in Al alloy gravity die castings

This research aimed to study the formation and distribution of oxide-related defects in the gravity die casting process of an AlSi7Cu0.5Mg alloy by using experimental and numerical investigations. Metallographic and image analysis techniques were conducted to map the distribution of oxide inclusions inside the casting at the microscopic level. Numerical simulations were used to analyse the filling and solidification stages, and to foresee the turbulence of the melt and the formation of the oxide defects. The results show that most of the defects were correlated with the oxide layers or bubbles entrained inside the liquid metal. The accuracy of the numerical code in simulating the metal fluid-dynamic behaviour and the heat transfer was verified, and the results were in agreement with the experimental findings. The numerical distribution of defects was consistent with the experimental results, proving that the model successfully predicted the formation of oxide-related defects.

Evaluation of Residual Stress in Die Castings of Al-Si-Cu Alloy Considering Material Composition Change in Thickness Direction

This study investigated a method for accurately predicting the residual stress in die castings manufactured using aluminum alloy. To account for the mechanical properties caused by the material composition differences that occur in the thickness direction of the die castings, a model split in the thickness direction was used in the simulation model. Norton’s law was applied to the constitutive equation of the material, and the stress relaxation phenomenon was examined. The composition of Al-Si-Cu alloy (JIS-ADC12) die castings in the thickness direction were analyzed using scanning electron microscopy and energy dispersive X-ray spectroscopy (SEM-EDS), and differences in composition were confirmed. As a result of calculating the residual stress using the simulation, it was possible to calculate the residual stress that could not be reproduced by the simulation model of uniform composition. This suggested that the difference in mechanical properties of die castings in the micro-region influences the residual stress.

Formation of Die Soldering and the Influence of Alloying Elements on the Intermetallic Interface

Die soldering of die castings is a serious problem in the aluminum casting industry. The precise mechanism, the influence of the alloy composition, and the options for prevention have not yet been fully elaborated. A well-established solution for alloys with low iron content is the addition of manganese. However, up to 0.8 wt.% is necessary, which increases the amount of brittle phases in the material and consequently reduces ductility. Immersion tests with 1.2343 tool steel and pure aluminum as well as a hypoeutectic AlSi-alloy with Mn, Mo, Co, and Cr additions were carried out to systematically investigate the formation of die soldering. Three different intermetallic layers and a scattered granular intermetallic phase formed at the interface between steel and Al-alloy after immersion into the melt for a duration of 6 min at 710 °C. The combined presence of the irregular, needle-shaped β-Al5FeSi phase and the surrounding alloy was responsible for the bond between the two components. Mn and Mo inhibited the formation of the β-phase, and instead promoted the αC-Al15(Fe,X)3Si2 phase. This led to an evenly running boundary to the AlSi-alloy and thus prevented bonding. Cr has proven to be the most efficient addition against die soldering, with 0.2 wt.% being sufficient. Contrary to the other elements investigated, Cr also reduced the thickness of the intermetallic interface.