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1
Content available Influence of plunger motion profile of high pressure die casting on the casting porosity and solidification rate
Żak Katarzyna, Dańko Rafał, Żak Paweł L., Kowalczyk Wojciech
Bulletin of the Polish Academy of Sciences. Technical Sciences
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2023
|
Vol. 71, nr 5
art. no. e147339
EN
The high pressure die casting (HPDC) is a technique that allows us to produce parts for various sectors of industry. It has a great application in such sectors as automotive, energy, medicine, as the HPDC allows us to produce parts very fast and very cheaply. The HPDC casting quality depends on many parameters. The parameters among others, are cast alloy alloy metallurgy, filling system design, casting technology elements geometry and orientation, as well as, machine operation settings. In the article, different plunger motion schemes of the HPDC machine were taken into account. Analyses lead to learning about plunger motion influence on the casting porosity and solidification process run. Numerical experiments were run with the use of MAGMASoft® simulation software. Experiments were performed for industrial casting of water pump for automotive. Main parameter taken into account was maximal velocity of the plunger in the second phase. The analysis covered porosity distribution, feeding time through the gate, temperature field during whole process, solidification time. Cooling curves of the casting in chosen points were also analysed. Obtained results allow us to formulate conclusions that connect plunger motion scheme, gate solidification time and the casting wall thickness on the solidification rate and porosity of the casting.
2
Content available Influence of Defects on Deformation Behavior of High-Pressure Die-Casting Magnesium Alloys
Braszczyńska-Malik Katarzyna
Archives of Foundry Engineering
|
2023
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Vol. 23, iss. 2
10--14
EN
The results of investigations of defects in AME-series magnesium alloys produced by the high-pressure die-casting method are presented. The analyzed magnesium alloys contain about 5 wt% aluminum and 1-5 wt% rare earth elements introduced in the form of mischmetal. The casts were fabricated using a regular type cold-chamber high-pressure die-casting machine with a 3.2 MN locking force. The same surfaces of the casts were analyzed before and after the three-point bending test in order to determine the influence of the gas and shrinkage porosity on the deformation behavior of the alloys. The obtained results revealed that the most dangerous for the cast elements is the shrinkage porosity, especially stretched in the direction perpendicular to the that of the tensile stress action. Additionally, the influence (Mg) solid solution and its interaction on the cracking process was described [alpha]  of deformation twins arise in the dendrites of the primary.
3
Content available Effect of Maximum Piston Velocity on Internal Homogeneity of AlSi9Cu3(Fe) Alloy Processed by High-Pressure Die Casting
Matejka Marek, Bolibruchowá Dana, Podprocká R.
Archives of Foundry Engineering
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2022
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Vol. 22, iss. 4
34--40
EN
High-pressure die casting results in a high quality surface and good mechanical properties of castings. Under the effect of pressure, integral and solid castings are achieved without a large number of foundry defects. The correct and proper setting of technological parameters plays a very important role in minimizing casting defects. The aim of the presented article is to determine the optimum maximum piston velocity for a casting in the high-pressure casting process with two height variants, depending on their internal quality. It is because the internal quality of particular castings is important in terms of proper functionality in operations where the biggest problem is the porosity of the casting. The main cause of porosity formation is the decreasing solubility of gases (most often hydrogen) during the melt solidification. Solubility represents the maximum amount of gas that can dissolve in a metal under equilibrium conditions of temperature and pressure. Macroporosity and microporosity were determined from the sections of the surfaces in the determined zones of the castings. Here, the results was that the macroporosity decreased with increasing piston velocity. Ideal microstructure was evaluated at a piston velocity of 3 m/s for both types of castings. On the other hand, the increase in tube size has shown that velocities of 3 m/s and higher, the tube is more prone to macroporosity formation. The highest hardness was achieved at the piston velocity of 2 m/s at both tube lengths.
4
Content available A Study of Microstructure and Porosity Formation in High-Pressure Die-Casting
Matejka Marek, Bolibruchová D., Podprocká R.
Archives of Foundry Engineering
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2021
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Vol. 21, iss. 4
127--130
EN
The technology of high-pressure die-casting (HPDC) of aluminum alloys is one of the most used and most economical technology for mass production of castings. High-pressure die-casting technology is characterized by the production of complex, thin-walled and dimensionally accurate castings. An important role is placed on the effective reduction of costs in the production process, wherein the combination with the technology of high-pressure die-casting is the possibility of recycling using returnable material. The experimental part of the paper focuses on the analysis of a gradual increase of the returnable material amount in combination with a commercial purity alloy for the production of high-pressure die-castings. The returnable material consisted of the so-called foundry waste (defective castings, venting and gating systems, etc.). The first step of the experimental castings evaluation consisted of numerical simulations, performed to determine the points of the casting, where porosity occurs. In the next step, the evaluation of areal porosity and microstructural analysis was performed on experimental castings with different amounts of returnable material in the batch. The evaluation of the area porosity showed only a small effect of the increased amount of the returnable material in the batch, where the worst results were obtained by the casting of the alloy with 90% but also with 55% of the returnable material in the batch. The microstructure analysis showed that the increase in returnable material in the batch was visibly manifested only by a change in the morphology of the eutectic Si.
5
Content available Effect of parameters of high-pressure die casting on occurrence of casting nonconformities in sleeves of silumin alloy EN AB 47100
Pałyga Ł., Stachowicz M., Granat K.
Archives of Metallurgy and Materials
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2017
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Vol. 62, iss. 1
373--378
EN
The paper presents a research on the effect of extreme - for the technology of the considered silumin EN AB 47100 - parameters of high-pressure die casting on occurrence of casting nonconformities. Considered was influence of the way of assembling the mould cooled-down to 140-160°C, non-standard for the selected casting, and pouring temperature in the range of 705 to 720°C (higher than the recommended) of non-refined alloy. The castings were prepared with use of a high-pressure casting machine made by Kirov with mould closing force of 2500 kN. Occurrence of nonconformities was evaluated on properly prepared specimens taken from the castings manufactured with various parameters of the injection piston and various multiplication pressures. The results were subjected to quantitative and qualitative analyses of casting nonconformities and distribution of major alloying elements. It was found that proper selection of working parameters of the casting machine, in spite of disadvantageous pouring conditions, makes it possible to reduce occurrence of some casting defects, like shrinkage cavities and porosity, to improve tightness of castings even when the alloy refining process is omitted.
6
Content available Analiza wtrąceń niemetalicznych w odlewach ze stopu AZ91 wykonanych z udziałem złomu obiegowego w procesie wysokociśnieniowego odlewania
Konopka Z., Chojnacki A.
Prace Instytutu Odlewnictwa
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2016
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Vol. 56, no. 4
321--328
PL
W artykule przedstawiono wyniki badań wpływu udziału złomu obiegowego we wsadzie stopu AZ91 na zmianę struktury odlewów wykonanych metodą wysokociśnieniowego odlewania, ze szczególnym uwzględnieniem tworzenia się wtrąceń niemetalicznych. Na podstawie obserwacji wtrąceń metodą mikroskopii skaningowej określono skład chemiczny tych wtrąceń w wytopach z różnym udziałem złomu obiegowego we wsadzie.
EN
The article presents research results of the process foundry return influence in the AZ91 alloy charge on the change in the structure of castings made by the high-pressure casting method, with special consideration of the formation of non-metallic inclusions. Based on the observations of inclusions by the scanning microscopy method, the chemical composition of the inclusions in melts with different process scrap contents in the charge was determined.
7
Content available Mg-Al-RE Magnesium Alloys for High-Pressure Die-Casting
Braszczyńska-Malik K.
Archives of Foundry Engineering
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2014
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Vol. 14, iss. 2
49--52
EN
Experimental Mg-Al-RE type magnesium alloys for high-pressure die-casting are presented. Alloys based on the commercial AM50 magnesium alloy with 1, 3 and 5 mass % of rare earth elements were fabricated in a foundry and cast in cold chamber die-casting machines. The obtained experimental casts have good quality surfaces and microstructure consisting of an α(Mg)-phase, Al11RE3, Al10RE2Mn7 intermetallic compound and small amount of α+γ eutectic and Al2RE phases.
8
Content available Lost Cores for High-Pressure Die Casting
Jelinek P., Adámková E.
Archives of Foundry Engineering
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2014
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Vol. 14, iss. 2
101--104
EN
Development of salt cores prepared by high-pressure squeezing and shooting with inorganic binders has shown a high potential of the given technology even for high-pressure casting of castings. Strength, surface quality of achieved castings, and solubility in water become a decisive criterion. The shape and quality of grain surface particularly of NaCl – cooking salts that can be well applied without anticaking additives has shown to be an important criterion. Thus the salt cores technology can cover increasingly growing demands for casting complexity especially for the automobile industry.
9
Content available remote The new foundry line for magnesium alloys high-pressure die-casting
Błaszczyk-Malik K. N., Walczak W., Braszczyński J.
Archives of Foundry Engineering
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2008
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Vol. 8, iss. 1
27-30
EN
The new foundry line for high-pressure die-casting of magnesium alloys constructed in the "SILUM" Foundry (Opojowice, Poland) is described. In the process cold chamber die-casting machines are used. The experimental casts and the radiators fabricated using the new cold chamber die-casting line are presented as the final results. The new production line allows to obtain good quality magnesium casts.
10
Content available remote echanical properties of high-pressure die-casting AZ91 magnesium alloy
Braszczyńska-Malik K. N., Zawadzki I., Walczak W., Braszczyński J.
Archives of Foundry Engineering
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2008
|
Vol. 8, iss. 4
15-18
EN
Results of mechanical properties of high-pressure die-casting AZ91 magnesium alloy are presented. Performed examinations allowed to determine influence of plunger velocity in the first and second stage and intensification pressure on the ultimate tensile strength (UTS), yield strength (YS), elongation (A5 and Agt), Brinell hardness (HB) and impact strength (IS) of samples cast on 320 tone cold chamber machine. Obtained results revealed the highest properties at median used parameters and also the most powerful effect of plunger velocity in the first stage. The maximum values of mechanical properties obtained from the performed experiments were: UTS 250 MPa, YS 160 MPa, A5 7%, 70 HB, IS 7 J.
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