Finite element analysis for die casting parameters in high-pressure die casting process

The gating system and the overflow system were designed according to the casting structure during high pressure die casting(HPDC) process. The simulation was carried out by ProCAST software to visualize the injection chamber pre-crystallization and the flow of molten metal. The main work is to research four die casting process parameters, i.e. injection temperature, low-pressure velocity, high-and low-pressure velocity’s switching position, and high-pressure velocity. Experimental results show that the higher injection temperature and lowpressure velocity can mitigate the pre-crystallization of the injection chamber. However, when the low-pressure velocity exceeds 0.2 m·s-1, the air entrapment in the chamber occurs. Besides, when the high-pressure velocity is greater than 2.5 m·s-1, the overflow channel at the final filling position is covered by the liquid metal too early. Finally, the injection temperature of 650 °C, the low-pressure velocity of 0.2 m·s-1, the high-and low-pressure velocity’s switching position of 320 mm and the high-pressure velocity of 2 m·s-1 are obtained as the optimal parameters by the software simulation, which has been verified by actual production.

Compressive behavior of NiAl/(Cr,Mo)Hf alloy prepared by high-pressure die casting and hot isostatic pressing

The NiAl-28Cr-5.85Mo-0.15Hf alloy was prepared by high-pressure die casting (HPDC) and subsequent hot isostatic pressing(HIP), and tested for compressible strength and fracture behavior at 300-1 373 K. The results show that the elevated temperature 0.2% compressible yield strength as well as the room-temperature compressible fracture strain of as-HIP alloy are larger than those of the same alloy prepared by directional solidification (DS). It suggests that the fine structures with a homogeneous distribution of fine Cr (Mo) and Hf-rich phase created by high-pressure die casting lead to these improvements.

High-tenacity in-situ Ti/Zr-based bulk metallic glasses composites fabricated by industrial high-pressure die casting

The glass-forming ability and mechanical properties of metallic glasses and their composites are well known to be sensitive to the preparation conditions and are highly deteriorated by industrial preparing conditions such as low-purity raw materials and low vacuum.Here,we showed that a series of in-situ bulk metallic glass composites(BMGCs)which exhibit excellent ductility and segmental work hardening were successfully developed utilizing a high vacuum high-pressure die casting(HV-HPDC)technology along with industrial-grade raw materials.The tensile properties of these BMGCs are systematically investigated and correlated with the alloy microstructure.As compared with the copper mold suction casting method,the volume fraction difference of the dendrite phase for the BMGCs with the same composition is not significant when fabricated by the HV-HPDC,whereas the size of theβ-phase is generally larger.Insitu BMGCs with the composition of Ti_(48)Zr_(20)(V_(12/17)Cu_(5/17))19 Be 13 obtained by the HV-HPDC process show ductility up to 11.3%under tension at room temperature and exhibit a certain amount of work hardening.Two conditions need to be met to enable the BMGCs,which are prepared by vacuum die-casting to retain favorable ductility:(1)The volume fraction ofβphase stays below 62%±2%;(2)The equiaxed crystals with a more uniform size in the range of 5-10μm.Meanwhile,the results of the present study provided guidance for developing BMGCs with good ductile properties under industrial conditions.

Effect of slow shot speed on externally solidified crystal,porosity and tensile property in a newly developed high-pressure die-cast Al-Si alloy

The effect of slow shot speed on externally solidified crystal(ESC),porosity and tensile property in a newly developed high-pressure die-cast Al-Si alloy was investigated by optical microscopy(OM),scanning electron microscopy(SEM)and laboratory computed tomography(CT).Results showed that the newly developed AlSi9MnMoV alloy exhibited improved mechanical properties when compared to the AlSi10MnMg alloy.The AlSi9MnMoV alloy,which was designed with trace multicomponent additions,displays a notable grain refining effect in comparison to the AlSi10MnMg alloy.Refining elements Ti,Zr,V,Nb,B promote heterogeneous nucleation and reduce the grain size of primaryα-Al.At a lower slow shot speed,the large ESCs are easier to form and gather,developing into the dendrite net and net-shrinkage.With an increase in slow shot speed,the size and number of ESCs and porosities significantly reduce.In addition,the distribution of ESCs is more dispersed and the net-shrinkage disappears.The tensile property is greatly improved by adopting a higher slow shot speed.The ultimate tensile strength is enhanced from 260.31 MPa to 290.31 MPa(increased by 11.52%),and the elongation is enhanced from 3.72%to 6.34%(increased by 70.52%).

Compression properties of cost-efficient porous expanded clay reinforced AA7075 syntactic foams fabricated by industrial-oriented die casting technology

In today’s manufacturing industries,hard competition between rival firms makes it compulsory for researchers to design lighter and cheaper machine components due to the megatrends of cost-effectiveness and anti-pollution.At this point,aluminum syntactic foams(ASFs)are new-generation engineering composites and come into the upfront as a problem-solver.Owing to their features like low density,sufficient elongation,and perfect energy absorption ability,these advanced foams have been considerably seductive for many industrial sectors nowadays.In this study,an industrial-oriented automatic die casting technology was used for the first time to manufacture the combination of AA7075/porous expanded clay(PEC).Micro evaluations(optical and FESEM)reveal that there is a homogenous particle distribution in the foam samples,and inspections are compatible with the other ASF studies.Additionally,T6 aging heat treatment was operated on one half of the produced foams to explore the probable impact of aging on the compressive responses.Attained results show that PEC particles can be an alternative to expensive hollow spheres used in the previous works.Besides,a favorable relationship is ascertained between the aging treatment and mechanical properties such as compression strength and plateau strength.

Microstructures and mechanical properties of a newly developed high-pressure die casting Mg-Zn-RE alloy

A newly developed Mg-4Zn-2La-3Y alloy with high strength was fabricated by high-pressure die casting method,and its microstructures were thoroughly studied using transmission electron microscopy.The results demonstrate that it owns fine grains and approximately highly interconnected intermetallic phase skeletons,and exhibits ultra-high strength at both room and high temperatures.Interestingly,the eutectic intermetallic skeleton of this alloys is consisted of numerous fine particles,which are mainly consisted of two intermetallic phases,namely W and Mg12RE.Multiple{101}twins and SFs were found in the Mg12RE phase while a few of SFs in the W phase.Additionally,minor long-period stacking ordered phase was observed in the eutectoid phase,and it probably nucleated on the Mg12RE phase following a certain OR as(0002)14H//(110)Mg12REand[1120]14H//[111]Mg12RE,or(0002)14H//(211)Mg12REand[1120]14H//[111]Mg12RE.This special intermetallic skeleton with many interfaces and planar faults can efficiently transfer dislocations across grain boundaries,and this is the key factor for the outstanding mechanical properties of the studied alloy.

Mold Filling and Prevention of Gas Entrapment in High-pressure Die-casting

这篇论文论述由 X 光检查衍射填特殊设计的 die-casting 的模子的直接观察的一些结果，包括有数字模拟的比较。基于作者讨论怎么阻止煤气的陷阱并且建议新方法的如此的工作。

Shear-accelerated crystallization of glass-forming metallic liquids in high-pressure die casting

As one of the most important forming technologies for industrial bulk metallic glass (BMG) parts withcomplex shapes, high-pressure die casting (HPDC) can fill a die cavity with a glass-forming metallic liquidin milliseconds. However, to our knowledge, the correlation between flow and crystallization behavior inthe HPDC process has never been established. In this study, we report on the solidification behavior ofZr_(55)Cu_(30)Ni_(5)Al_(10) glass forming liquid under various flow rates. Surprisingly, the resulting alloys display adecreasing content of amorphous phase with increase of flow rate, i.e. increase of cooling rate, suggestingthat crystallization kinetics of glass-forming metallic liquids in the HPDC process is strongly dependenton the flow field. Analysis reveals that the accelerated crystallization behavior is mainly ascribed to therapid increase in viscosity with a decreasing temperature as well as to the huge shear effect in the glassforming liquid at the end stage of the filling process when the temperature is close to the glass-transitionpoint;this results in a transition from diffusion- to advection-dominated transport. The current investigation suggests that flow-related crystallization must be considered to assess the intrinsic glass-formingability of BMGs produced via HPDC. The obtained results will not only improve the understanding ofcrystallization dynamics but also promote the high-quality production and large-scale application of BMGparts.

Effects of runner design and pressurization on the microstructure of a high-pressure die cast Mg-3.0Nd-0.3Zn-0.6Zr alloy

To clarify the relationship between externally solidified crystals(ESCs)and other defects,e.g.,defect bands and pores,two dimensional(2D)and three dimensional(3D)characterization methods were adopted to analyze castings produced using a modified ingate system equipped with and without an ESC collector.The reduction of ESCs strongly reduced defect band width and shrinkage pore quantity.By reducing the quantity and size of ESCs,net-shrinkage pores were transformed into isolated island-shrinkage pores.We determined via statistical analysis that the mechanical properties of high pressure die castings were strongly related to the size and fraction of the ESCs rather than porosity volume.The reduction of ESCs also caused tensile transgranular fracture modes to transform into intergranular fracture modes.Additionally,casting pressurization strongly reduced pore morphology,volume,and size.

Effects of magnesium and copper additions on tensile properties of Al-Si-Cr die casting alloy under as-cast and T5 conditions

Aluminum high pressure die casting(HPDC)technology has evolved in the past decades,enabling stronger and larger one-piece casting with significant part consolidation.It also offers a higher design freedom for more mass-efficient thin-walled body structures.For body structures that require excellent ductility and fracture toughness to be joined with steel sheet via self-piercing riveting(for instance,shock towers and hinge pillars,etc.),a costly T7 heat treatment comprising a solution heat treatment at elevated temperatures(450℃-500℃)followed by an over-ageing heat treatment is needed to optimize microstructure for meeting product requirement.To enable cost-efficient mass production of HPDC body structures,it is important to eliminate the expensive T7 heat treatment without sacrificing mechanical properties.Optimizing die cast alloy chemistry is a potential solution to improve fracture toughness and ductility of the HPDC components.The present study intends to tailor the Mg and Cu additions for a new Al-Si-Cr type die casting alloy(registered as A379 with The Aluminum Association,USA)to achieve the desired tensile properties without using T7 heat treatment.It was found that Cu addition should be avoided,as it is not effective in enhancing strength while degrades tensile ductility.Mg addition is very effective in improving strength and has minor impact on tensile ductility.The investigated Al-Si-Cr alloy with a nominal composition of Al-8.5wt.%Si-0.3wt.%Cr-0.2wt.%Fe shows comparable tensile properties with the T7 treated AlSi10MnMg alloy which is currently used for manufacturing shock towers and hinge pillars.

Effect of vacuum on porosity and mechanical properties of high-pressure die-cast pure copper

Pure copper tensile bars were produced by conventional die casting(HPDC) and vacuum-assist die casting(VADC) processes. Porosity and mechanical properties were investigated by using optical microscopy(OM), scanning electron microscopy(SEM), energy dispersive spectroscopy(EDS), X-ray computed tomography(XCT) and tensile tester. Results show that porosities including gas porosity and shrinkage porosity could be observed in copper castings. Since the application of vacuum could reduce filling related gas entrapment and facilitate solidification due to the increased heat transfer between metal and die, both number and size of the entrapped gases, as well as shrinkage porosities were significantly reduced in vacuum-assist die castings of pure copper. The porosity fraction decreased from 2.243% to 0.875% compared with that of the conventional die casting. Besides, mechanical properties were improved significantly, i.e., by 15% for ultimate tensile strength and three times for elongation.

Microstructure and mechanical properties of melt-conditioned high-pressure die-cast Mg-Al-Ca alloy

A new shape casting process,melt-conditioned high-pressure die-casting(MC-HPDC) was developed.In this process,liquid metal was conditioned under intensively forced convection provided by melt conditioning with advanced shear technology(MCAST) unit before being transferred to a conventional cold chamber high-pressure die-casting(HPDC) machine for shape casting. The effect of melt conditioning was investigated,which was carried out both above and below the liquidus of the alloy,on the microstructure and properties of a Mg-Al-Ca alloy(AZ91D+2%Ca(mass fraction) ,named as AZX912) .The results show that many coarse externally-solidified crystals(ESCs) can be observed in the centre of conventional HPDC samples,and hot tearing occurs at the inter-dendritic region because of the lack of feeding.With the melting conditioning,the MC-HPDC samples not only have considerably refined size of ESCs but also have significantly reduced cast defects,thus provide superior mechanical properties to conventional HPDC castings.The solidification behaviour of the alloy under different processing routes was also discussed.

Characterization on the formation of porosity and tensile properties prediction in die casting Mg alloys

The 3D visualization of the porosity in high-pressure die casting(HPDC)Mg alloys AZ91D and Mg4Ce2Al0.5Mn(EA42)was investigated by X-ray computed tomography.It was demonstrated that the volumetric porosity at the near-gate location for alloy EA42 was significantly higher than that far from the gate location.This difference resulted from the low valid time during intensified casting pressure conditions.Specimens of alloy EA42 exhibited a narrow pore distribution in the side view(~0.5 mm)compared to the wide distribution(~1.8 mm)of alloy AZ91D,which was mainly attributed to the formation mechanism of the defect band.The formation of microporosity in the defect band of alloy EA42 was inhibited because of the significant latent heat released by a large amount of the Al11Ce3phase segregated in the defect band during solidification.Additionally,an effective estimator(Z-Propagation)was introduced,which is proposed to predict the projected area fraction of the porosity(f)involved during tensile failure with better effectiveness compared with traditional methods based on the actual fractured surface.By coupling the Z-Propagation method with the critical local strain model,the logarithmic fracture strain and true fracture stress of the specimens were predicted within 3.03%and 1.65%of the absolute value of the average relative error(AARE),respectively.

High thermal conductivity and high strength magnesium alloy for high pressure die casting ultrathin-walled components

With the rapid development of 3C industries,the demand for high-thermal-conductivity magnesium alloys with high mechanical performance is increasing quickly.However,the thermal conductivities of most common Mg foundry alloys(such as Mg-9wt%-1wt%Zn)are still relatively low.In this study,we developed a high-thermal-conductivity Mg-4Al-4Zn-4RE-1Ca(wt%,AZEX4441)alloy with good mechanical properties for ultrathin-walled cellphone components via high-pressure die casting(HPDC).The HPDC AZEX4441 alloy exhibited a fine homogeneous microstructure(average grain size of 2.8μm)with granular Al_(11)RE_(3),fibrous Al_(2)REZn_(2),and networked Ca_(6)Mg_(2)Zn_(3) phases distributed at the grain boundaries.The room-temperature thermal conductivity of the HPDC AZEX4441 alloy was 94.4 W·m^(-1)·K^(-1),which was much higher than 53.7 W·m^(-1)·K^(-1) of the HPDC AZ91D alloy.Al and Zn in the AZEX4441 alloy were largely consumed by the formation of Al_(11)RE_(3),Al_(2)REZn_(2),and Ca_(2)Mg_(6)Zn_(3) phases because of the addition of RE and Ca.Therefore,the lattice distortion induced by solute atoms of the AZEX4441 alloy(0.171%)was much lower than that of the AZ91D alloy(0.441%),which was responsible for the high thermal conductivity of the AZEX4441 alloy.The AZEX4441 alloy exhibited a high yield strength of~185 MPa,an ultimate tensile strength of~233 MPa,and an elongation of~4.2%.This result indicated that the tensile properties were comparable with those of the AZ91D alloy.Therefore,this study contributed to the development of high-performance Mg alloys with a combination of high thermal conductivity,high strength,and good castability.

Gating system optimization of high pressure die casting thin-wall AlSi10MnMg longitudinal loadbearing beam based on numerical simulation

High pressure die casting(HPDC) is a kind of near net shape manufacturing method. However, air entrapment in HPDC parts has serious effects upon the casting quality. In order to reduce the air entrapment defects in a AlSi10 MnMg alloy thin-wall longitudinal load-bearing beam produced by HPDC, different gating systems were designed and simulated by software Flow-3D to evaluate the entrapped air. Simulation results showed that when the beam is produced by the original designed gating system with a middle ingate, there exist obvious air entrapments in the critical area; the volume of air entrapment was reduced by replacing the middle ingate to an overflow well, and the filling of molten metal became more stable. When the middle ingate was removed for further improvement, the volume of air entrapment was decreased drastically. The parts with glossy surface and good microstructure have been successfully produced by using the final optimized gating system based on simulation results.

Determination of interfacial heat transfer coefficient and its application in high pressure die casting process

In this paper,the research progress of the interfacial heat transfer in high pressure die casting(HPDC)is reviewed.Results including determination of the interfacial heat transfer coefficient(IHTC),influence of casting thickness,process parameters and casting alloys on the IHTC are summarized and discussed.A thermal boundary condition model was developed based on the two correlations:(a)IHTC and casting solid fraction and(b)IHTC peak value and initial die surface temperature.The boundary model was then applied during the determination of the temperature field in HPDC and excellent agreement was found.

Die Casting Mold Design of the Thin-walled Aluminum Case by Computational Solidification Simulation

Recently, demand for the lightweight alloy in electric/electronic housings has been greatly increased. However, among the lightweight alloys, aluminum alloy thin-walled die casting is problematic because it is quite difficult to achieve sufficient fluidity and feedability to fill the thin cavity as the wall thickness becomes less than 1mm. Therefore, in this study, thin-walled die casting of aluminum （Al-Si-Cu alloy： ALDC 12） in size of notebook computer housing and thickness of 0.8 mm was investigated by solidification simulation （MAGMA soft） and actual casting experiment （Buhler Evolution B 53D）. Three different types of gating design, finger, tangential and split type with 6 vertical runners, were simulated and the results showed that sound thin-walled die casting was possible with tangential and split type gating design because those gates allowed aluminum melt to flow into the thin cavity uniformly and split type gating system was preferable gating design comparing to tangential type gating system at the point of view of soundness of casting and distortion generated after solidification. Also, the solidification simulation agreed well with the actual die-casting and the casting showed no casting defects and distortion.

Performance of Semi-solid Slurry Produced by Twin-screw Stirring Mixer and Rheo-diecasting Process of AZ91D Alloy

The microstructure of semi-solid slurry of AZ91D alloy, which was produced by twin-screw stirring mixer under the different parameters, was investigated.Rheoforming by cold chamber die casting process was performed thereafter. The results indicate that with decreasing of the barrel temperature of the mixer and the pouring temperature of molten Mg alloy, the solid fraction of semi-solid slurry increases and the size of non-dendritic grains becomes smaller. While the shear rate increases, the solid fraction of semi-solid slurry decreases. The tensile strength and elongation of metal rheoformed by die casting are higher by about 37% and 44% respectively than those produced by conventional liquid die casting.

Design and Verification of an Auxiliary System for High Vacuum Die Casting

Vacuum die casting is the optimal method to produce high quality aluminum alloy components.At present,there are still very few systematic studies on vacuum die casting theory and equipment design.On the basis of the existing theories of the vacuum die casting pumping and venting systems,a simplified model is established in this research.The model has an aggregate unit consisted of ＂vacuum pump ＋ buffer tank＂ and a cylindrical container（including the shot sleeve,cavity and exhaust channel）.The theoretical analysis is carried out between the cavity pressure and the pumping time under different volume models.An auxiliary system for high vacuum die casting is designed based on the above analysis.This system is composed of a vacuum control machine and a new vacuum stop valve.The machine has a human-computer control mode with ＂programmable logic controller（PLC） ＋ touch screen＂ and a real-time monitoring function of vacuum degree for buffer tank and die cavity.The vacuum stop valve with the ＂compressed gas ＋ piston rod ＋ labyrinth groove＂ structure can realize the function of whole-process vacuum venting.The new system shows great advantages on vacuuming the cavity with a much faster speed by making tests on an existing die casting mold and a 250 t die casting machine.A die cavity pressure less than 10 kPa can be reached within 0.8 s in the experiment and the porosity of castings can be greatly decreased.The systematic studies on vacuum die casting theory and equipment have a great guiding significance for high vacuum die casting,and can also be applied to other high vacuum forming in related theoretical and practical research.

LOW CYCLE FATIGUE BEHAVIOR OF AZ91HP ALLOY IN AS HIGHP RESSURE DIE CASTING

Fully reversed total strain-controlled low-cycle fatigue tests were conducted at room temperature in air to study the fatigue behavior of AZ91HP magnesium alloy in as high pressure die casting and subsequently heat treatment. All the specimens in different heat histories exhibit cyclic strain hardening in different degrees. It is difficult to distinguish the fatigue behavior of the die casting specimens from that of the solution aging specimens. The solution treated specimens show longer fatigue life at high strain amplitude and shorter fatigue life at low strain amplitude than the die casting and solution aging specimens though they have the lowest yield strength with higher strain hardening. Fatigue fracture surfaces for strain amplitude larger than 0.005 show very similar to those found by monotonic tensile tests. The SEM examination reveals that the regions of fatigue crack growth and final fracture can be characterized by quasi-cleavage mechanisms, but some shallow dimples, slip bands and secondary cracks are found on the fracture surface in the fracture crack growth areas.