Migration of crystals during the filling of semi-solid castings

In cold-chamber high-pressure die castings (HPDC), the microstructure consists of coarse externally solidified crystals (ESCs) that are commonly observed in the central region of cross sections. In the present work, controlled laboratory scale casting experiments have been conducted with particular emphasis on the flow and solidification conditions. An A356 aluminum alloy was used to produce castings by pouring semi-solid metal through a steel die. Microstructures similar to those encountered in HPDC have been produced and the resulting microstructure is found to depend on the melt and die temperature: (1) the fraction of ESCs determines the extent of migration to the central region; (2) a maximum packing determines the area fraction of ESCs in the center; and (3) the die temperature affects the position of the ESCs—a higher die temperature can induce a displaced ESC distribution. It is found that the migration of crystals to the central region requires a flow, which is constrained at all melt/die interfaces. Furthermore, potential lift mechanisms are discussed. An assessment of the Saffman lift force on individual particles shows it has no significant effect on the migration of ESCs.     

Migration of crystals during the filling of semi-solid castings

In cold-chamber high-pressure die castings (HPDC), the microstructure consists of coarse externally solidified crystals (ESCs) that are commonly observed in the central region of cross sections. In the present work, controlled laboratory scale casting experiments have been conducted with particular emphasis on the flow and solidification conditions. An A356 aluminum alloy was used to produce castings by pouring semi-solid metal through a steel die. Microstructures similar to those encountered in HPDC have been produced and the resulting microstructure is found to depend on the melt and die temperature: (1) the fraction of ESCs determines the extent of migration to the central region; (2) a maximum packing determines the area fraction of ESCs in the center; and (3) the die temperature affects the position of the ESCs—a higher die temperature can induce a displace ESC distribution. It is found that the migration of crystals to the central region requires a flow, which is constrained at all melt/die interfaces. Furthermore, potential lift mechanisms are discussed. An assessment of the Saffman lift force on individual particles shows it has no significant effect on the migration of ESCs. H.I. LAUKLI, Research Scientist, formerly with the Department of Materials Technology, NTNU, N-7491 Trondheim, Norway     

Mechanisms of Soldering Formation on Coated Core Pins

Die soldering is one of the major casting defects during the high-pressure die casting (HPDC) process, causing dimensional inaccuracy of the castings and increased downtimes of the HPDC machine. In this study, we analyzed actually failed core pins to determine the mechanism of soldering and its procedures. The results show that the soldering process starts from a local coating failure, involves a series of intermetallic phase formation from reactions between molten aluminum alloys and the H13 steel pin, and accelerates when an aluminum-rich, face-centered cubic (fcc) phase is formed between the intermetallic phases. It is the formation of the aluminum-rich fcc phase in the reaction region that joins the core pin with the casting, resulting in the sticking of the casting to the core pin. When undercuts are formed on the core pin, the ejection of castings from the die will lead to either a core pin failure or damages to the casting being ejected.     

The Effects of Microstructure Heterogeneities and Casting Defects on the Mechanical Properties of High-Pressure Die-Cast AlSi9Cu3(Fe) Alloys

Detailed investigations of the salient microstructural features and casting defects of the high-pressure die-cast (HPDC) AlSi9Cu3(Fe) alloy are reported. These characteristics are addressed to the mechanical properties and reliability of separate HPDC tensile bars. Metallographic and image analysis techniques have been used to quantitatively examine the microstructural changes throughout the tensile specimen. The results indicate that the die-cast microstructure consists of several microstructural heterogeneities such as positive eutectic segregation bands, externally solidified crystals (ESCs), cold flakes, primary Fe-rich intermetallics (sludge), and porosities. In addition, it results that sludge particles, gas porosity, as well as ESCs, and cold flakes are concentrated toward the casting center while low porosity and fine-grained structure is observed on the surface layer of the castings bars. The local variation of the hardness along the cross section as well as the change of tensile test results as a function of gage diameter of the tensile bars seem to be ascribed to the change of porosity content, eutectic fraction, and amount of sludge. Further, this behavior reflects upon the reliability of the die-cast alloy, as evidenced by the Weibull statistics.     

Microstructure and Corrosion Characterization of Squeeze Cast AM50 Magnesium Alloys

Squeeze casting of magnesium alloys potentially can be used in lightweight chassis components such as control arms and knuckles. This study documents the microstructural analysis and corrosion behavior of AM50 alloys squeeze cast at different pressures between 40 and 120 MPa and compares them with high-pressure die cast (HPDC) AM50 alloy castings and an AM50 squeeze cast prototype control arm. Although the corrosion rates of the squeeze cast samples are slightly higher than those observed for the HPDC AM50 alloy, the former does produce virtually porosity-free castings that are required for structural applications like control arms and wheels. This outcome is extremely encouraging as it provides an opportunity for additional alloy and process development by squeeze casting that has remained relatively unexplored for magnesium alloys compared with aluminum. Among the microstructural parameters analyzed, it seems that the β-phase interfacial area, indicating a greater degree of β network, leads to a lower corrosion rate. Weight loss was the better method for determining corrosion behavior in these alloys that contain a large fraction of second phase, which can cause perturbations to an overall uniform surface corrosion behavior.     

Feeding Mechanisms in High-Pressure Die Castings

This work focuses on understanding the feeding behavior during high-pressure die casting (HPDC). The effects of intensification pressure (IP) and gate thickness on the transport of material through the gate during the latter stages of HPDC were investigated using an AlSi3MgMn alloy. Microstructural characterization of the gate region indicated a marked change in feeding mechanism with increasing IP and gate size. Castings produced with a high IP or thick gate contained a relatively low fraction of total porosity, and shear band-like features existed through the gate, suggesting that semisolid strain localization in the gate is involved in feeding during the pressure intensification stage. When a low IP is combined with a thin gate, no shear band is observed in the gate and feeding is less effective, resulting in a higher level of porosity in the HPDC component. Although shear banding through the gate was found to reduce porosity in HPDC parts, if gates are not properly designed, deformation of the mushy zone through the gate can cause severe macrosegregation, large pores, and large cracks, which could severely reduce the performance of the component.     

Formation of defect bands in high pressure die cast magnesium alloys

Die cast magnesium components are being increasingly used worldwide because of the excellent castability and properties that magnesium alloys offer. High pressure die casting of thin-walled components is particularly suitable because of the excellent flow characteristics of molten magnesium alloys. Typical automotive applications for thin-walled castings include components such as instrument panels, steering wheels, door frames and seat frames. These applications require optimisation of the quality and performance of the castings. It has been found that bands of porosity or segregation which follow contours parallel to the surface of the casting are formed under certain casting conditions in thin-walled magnesium high pressure die castings. The presence of this type of defect can have a significant effect on the mechanical properties. This paper investigates the effect of varied casting conditions on casting integrity and the appearance of the bands. A rationale for understanding the origin of these defects is related to the solidification behaviour, the mushy zone rheological properties and the filling pattern of the casting with associated shearing of the mushy zone. Methods to optimise the process parameters to control the occurrence of the banded defects, and thereby optimise the quality of high pressure die cast magnesium components, are outlined.     

Neutron diffraction measurement of strain required for the onset of hot tearing in AZ91D magnesium alloy

Magnesium alloy castings are increasingly used in automotive, aerospace and electronics industries. These castings are mainly produced via high-pressure die-casting (HPDC). During this casting process, molten alloy solidifies within a rigid mold, which resists the alloy’s volumetric contraction. As a result, thermal and mechanical stresses develop in the casting and potentially lead to the nucleation of hot tears.     

Microstructure formation in high pressure die casting

In order to optimise the high pressure die casting (HPDC) process, more understanding of microstructure and defect formation is essential. This article gives an overview of the key microstructural features and the mechanisms of microstructure formation in this process. The incavity solidified grain size in HPDC can be as low as 10 μm, but externally solidified crystals (ESCs) as large as 200 μm are often also present. The eutectic microstructure is very fine with an interlamellar spacing around 500 nm. Bands of positive macrosegregation and sometimes with cracks/porosity, so-called defect bands, are also often observed. Intensification pressure (IP) is one of the major factors governing the porosity level in the casting. At high IP, defect bands form in the gate region and appear to be assisting the feeding during the intensification stage.     

Melt-Conditioned, High-Pressure Die Casting of Mg–Zn–Y Alloy

The liquid Mg–Zn–Y alloy was conditioned by an application of high-intensive shearing with a pair of intermesh twin screws prior to high-pressure die casting (HPDC). Melt conditioning produces a uniform microstructure with fine grain size and high integrity. The microstructure was analyzed thoroughly, and the solidification characteristics of the melt-conditioned HPDC (MC-HPDC) structure were discussed. The enhancement in I-phase precipitation and the improvement in mechanical properties of MC-HPDC Mg–Zn–Y alloy can be achieved through cyclic annealing.     

Relationship Between the 3D Porosity and β-Phase Distributions and the Mechanical Properties of a High Pressure Die Cast AZ91 Mg Alloy

Currently, most magnesium lightweight components are fabricated by casting as this process is cost effective and allows forming parts with complex geometries and weak textures. However, cast microstructures are known to be heterogeneous and contain unpredictable porosity distributions, which give rise to a large variability in the mechanical properties. This work constitutes an attempt to correlate the microstructure and the mechanical behavior of a high pressure die cast (HPDC) Mg AZ91 alloy, aimed at facilitating process optimization. We have built a stairway-shaped die to fabricate alloy sections with different thicknesses and, thus, with a range of microstructures. The grain size distributions and the content of β-phase (Mg₁₇Al₁₂) were characterized by optical and electron microscopy techniques as well as by electron backscatter diffraction (EBSD). The bulk porosity distribution was measured by 3D computed X-ray microtomography. It was found that the through-thickness microhardness distribution is mostly related to the local area fraction of the β-phase and to the local area fraction of the pores. We correlate the tensile yield strength to the average pore size and the fracture strength and elongation to the bulk porosity volume fraction. We propose that this empirical approach might be extended to the estimation of mechanical properties in other HPDC Mg alloys.     

The design of feed systems for thin-walled zinc high-pressure die castings

A number of methods have been devised for the design of feed systems in high-pressure die castings to optimize their mechanical properties. Most of these result in a decrease in the included gas porosity by having runners which decrease in area along the flow direction. Although the influence of the ingate design on matters such as surface quality of the casting and erosion of the die are well known, the ingate is not usually a critical part of design for optimizing mechanical properties. Nevertheless, it is known that the mechanical properties of pressure die castings made of zinc alloy 3 (Zn-4.lAl-0.05 Mg) can be improved by controlling ingate size and molten metal injection velocity. In this article, we describe a method for designing the ingate so as to optimize the mechanical properties.     

Influence of Grain Refinement on Slurry Formation and Surface Segregation in Semi-solid Al-7Si-0.3Mg Castings

This study aims to evaluate the effect of grain refinement on slurry formation and surface segregation in semi-solid castings produced by the Rheometal™ process. The effect of two grain refiners, Al-8B and Al-5Ti-1B, on the slurry α-Al grain size, shape factor and solid fraction was evaluated. The results suggest that the addition of a grain refiner can affect the solid fraction obtained in the Rheometal^TM process and, consequently, reduce the solute content near the casting surface. Grain refiner addition resulted in a larger fraction of α-Al grains ≤ 60 µm for the refined alloys compared with the unrefined alloy. Additionally, the growth of α-Al slurry globules was greater for the unrefined alloy compared with the refined alloy during solidification in the die-cavity. A more homogeneous and finer microstructure was observed near the surface in the grain-refined castings compared with the unrefined castings. Evidence of significant liquid penetration was identified in some α-Al globules, indicating that disintegration of α-Al globules may occur during the Rheometal™ casting process.

     

A laboratory evaluation of the construction of resin-bonded cast restorations

OBJECTIVE: To compare the effect of two construction techniques and two pattern materials on the fit of resin-bonded cast restorations. DESIGN: In-vitro study carried out by one operator. SETTING: Postgraduate university hospital. SUBJECTS AND METHODS: 65 nickel-chrome castings were constructed using refractory die and lift-off techniques with wax and acrylic resin pattern material. They were cemented onto master silver dies, embedded in self-curing acrylic resin and sectioned along their long axes. Interfacial distance between the master silver die and casting was measured. RESULTS: A significant different between the range of figures in each group (Mann-Whitney Test, P < 0.01) was found. Construction techniques can be ranked in order of fit of castings: 1. Refractory die, wax patterns: 42.6 microns (SD 12.03). 2. Refractory die, acrylic resin patterns: 53.7 microns (SD.16.06).3. Conventional technique, acrylic resin patterns: 85.5 microns (SD 31.62). 4. Lift-off technique, wax patterns: 139 microns (SD 53.15).5. Lift-off technique, acrylic patterns: 172.8 microns (SD 74.04). CONCLUSIONS: Castings constructed using refractory die technique and subsequently cemented resulted in a more accurate and less variable fit than those produced with the lift-off technique. Wax patterns lead to more accurate castings than acrylic resin and locating indentations may interfere with the cementation of castings when lift-off techniques are used.     

The effect of mold precession on channel and macro-segregation in ammonium chloride-water analog castings

Analog castings of two geometrical forms have been studied to observe the effect of continuously changing the direction of gravitational force on patterns of segregation. Molds of slab form, cooled on one side, and of cylindrical form, cooled at the base, were rotated axially at rates from 0 to 10 rpm with the axis of rotation tilted from 0 to 30 deg to the vertical: the development of “A” channel segregation in the former and of “freckel” channels in the latter were recorded photographically, while changes in bulk liquid concentration were followed over time periods up to one hour. It was observed that changing the direction of gravitation, slowly and continuously, markedly retarded or eliminated the formation of segregation channels and that consequent macrosegregation was also retarded and reduced. The application of the principle to foundry practice is discussed.     

Solidification Behavior of Intensively Sheared Hypoeutectic Al-Si Alloy Liquid

The effect of the processing temperature on the microstructural and mechanical properties of Al-Si (hypoeutectic) alloy solidified from intensively sheared liquid metal has been investigated systematically. Intensive shearing gives a significant refinement in grain size and intermetallic particle size. It also is observed that the morphology of intermetallics, defect bands, and microscopic defects in high-pressure die cast components are affected by intensive shearing the liquid metal. We attempt to discuss the possible mechanism for these effects.