Defect band formation in high pressure die casting AE44 magnesium alloy

The characteristics of defect bands in the microstructure of high pressure die casting (HPDC) AE44 magnesium alloy were investigated. Special attention was paid to the effects of process parameters during the HPDC process and casting structure on the distribution of defect bands. Results show that the defect bands are solute segregation bands with the enrichment of Al, Ce and La elements, which are basically in the form of Al₁₁RE₃ phase. There is no obvious aggregation of porosities in the defect bands. The width of the inner defect band is 4–8 times larger than that of the outer one. The variation trends of the distribution of the inner and outer defect bands are not consistent under different process parameters and at different locations of castings. This is due to the discrepancy between the formation mechanisms of double defect bands. The filling and solidification behavior of the melt near the chilling layer is very complicated, which finally leads to a fluctuation of the width and location of the outer defect band. By affecting the content and aggregation degree of externally solidified crystals (ESCs) in the cross section of die castings, the process parameters and casting structure have a great influence on the distribution of the inner defect band.