Mold-filling characteristics of AZ91 magnesium alloy in the low-pressure expendable pattern casting process |
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Authors: | H B Wu Z T Fan N Y Huang X P Dong X F Tian |
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Affiliation: | (1) State Key Laboratory Plastic Forming Simulation and Mold Technology, Huazhong University of Science and Technology, 430074 Wuhan, People’s Republic of China |
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Abstract: | The magnesium (Mg) alloy low-pressure expendable pattern casting (EPC) process is a newly developed casting technique combining
the advantages of both EPC and low-pressure casting. In this article, metal filling and the effect of the flow quantity of
inert gas on the filling rate in the low-pressure EPC process are investigated. The results showed that the molten Mg alloy
filled the mold cavity with a convex front laminar flow and the metal-filling rate increased significantly with increasing
flow quantity when flow quantity was below a critical value. However, once the flow quantity exceeded a critical value, the
filling rate increased slightly. The influence of the flow quantity of inert gas on melt-filling rate reveals that the mold
fill is controlled by flow quantity for a lower filling rate, and, subsequently, controlled by the evaporation of polystyrene
and the evaporation products for higher metal velocity. Meanwhile, the experimental results showed that the melt-filling rate
significantly affected the flow profile, and the filling procedure for the Mg alloy in the low-pressure EPC process. A slower
melt-filling rate could lead to misrun defects, whereas a higher filling rate results in folds, blisters, and porosity. The
optimized filling rate with Mg alloy casting is 140 to 170 mm/s in low-pressure EPC. |
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Keywords: | expandable pattern casting low-pressure casting magnesium alloy |
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