This document analyzes the effect of increased pressure on the porosity of die castings. Three castings of an aluminum alloy were produced with increasing pressures of 13 MPa, 22 MPa, and 25 MPa. Metallographic analysis found porosity levels of 3.73%, 2.09%, and 0.85% respectively, indicating that higher pressure leads to lower porosity. X-ray images confirmed fewer and smaller voids in castings with higher pressure. The study concludes that increased pressure is an important factor for improving casting quality by reducing porosity.
This document analyzes the effect of increased pressure on the porosity of die castings. Three castings of an aluminum alloy were produced with increasing pressures of 13 MPa, 22 MPa, and 25 MPa. Metallographic analysis found porosity levels of 3.73%, 2.09%, and 0.85% respectively, indicating that higher pressure leads to lower porosity. X-ray images confirmed fewer and smaller voids in castings with higher pressure. The study concludes that increased pressure is an important factor for improving casting quality by reducing porosity.
This document analyzes the effect of increased pressure on the porosity of die castings. Three castings of an aluminum alloy were produced with increasing pressures of 13 MPa, 22 MPa, and 25 MPa. Metallographic analysis found porosity levels of 3.73%, 2.09%, and 0.85% respectively, indicating that higher pressure leads to lower porosity. X-ray images confirmed fewer and smaller voids in castings with higher pressure. The study concludes that increased pressure is an important factor for improving casting quality by reducing porosity.
Elimination of Porosity of Die Casting by Increased
Pressure Function
Stefan Gaspar, Jan Pasko, Jozef Malik
Abstract A high pressure die casting technology of nonferrous metals and their alloys is one of the latest ones used in foundry industry. In accordance with a specific character of this production technology, the major casting defects are cavities and cold shuts. The presented contribution deals with analysis of increased pressure influence on porosity of castings. It is very important from the point of view of quality indexes of manufacturing. Keywords: pressure die casting, increased pressure, porosity, quality of production
1 Introduction In die casting production process, a higher attention is paid to die castings inner quality which is characterized by a type and range of casting related defects. The major cas- ting defects are cavities. These cavities are determined as bubbles of exogenous origin due to the gases and air inside a die trapped by a turbulent flow of a molten metal [7]. A die casting plunger velocity inside a filling chamber of a pressure die casting machine is one of the most significant factors of a pressure die casting. This velocity determines the regime of a die cavity filling, thus influencing both inner and surface quality of castings [8]. Emphasizing techno- logical parameters of a pressure die casting process, besides parameters referring to a die cavity filling, castings quality is affected by increased pressure exerted on a solidifying casting in the last phase of a casting process [4, 5]. The process of a hydrostatic pressure transfer into the die cavity is called increased pressure. The longer the solidi- fication time of the gating channel, the longer the pressure operates. [1, 3]. 2 Experimental methodics and applied materials The influence of increased pressure on the porosity of castings was verified with a horizontal cold chamber die casting machine of the Mller Weingarten 600 type. The verification of the influence of the increased pressure on the porosity was carried out with the casting illustrated in fig. 1, produced from the ENAC 47100 alloy, whose chemical composition corresponded with EN 1706 (STN 424310), table 1 [2]. The analyzed sampling castings were cast keeping to the constant and variable technological factors: Constant technological factors: plunger pressing velocity - 2,6 m.s -1
liquid alloy temperature - 708 C working temperature of a die - 199 C Variable technological factors: increased pressure p 1 = 13 MPa, p 2 =22 MPa, p 3 =25 MPa Based on the mentioned factors a set of castings was obtained and analyzed. A metallographic sample was taken from the same place of each casting as denoted by an arrow in fig. 2. Metallographic samples of all analyzed were 100 times enlarged under the OLYMPUS GX51 microscope and
processed by a computer software ImageJ. This computer software images taken from space evaluated a percentage ratio of porosity [2, 6].
Fig 1 Test sample of a die casting - flange for an electric motor Table 1 Chemical composition of the experimental cast of the applied alloy Chemical composition of the experimental cast of the applied alloy % of elements content Al Si Fe Cu Mn Mg 85,27 12,02 0,71 1,19 0,21 0,13 according to EN 1706 (STN 424310) the rest 10,5 - 13,5 max. 1,5 0,7 - 1,2 max. 0,55 max. 0,35 Cr Ni Zn Pb Sn Ti 0,02 0,02 0,35 0,02 0,03 0,03 according to EN 1706 (STN 424310) max. 0,1 max. 0,3 max. 0,55 max. 0,2 max. 0,1 max. 0,2
Fig. 2 Evaluation of the porosity of the sample No. 3.1 by the Image J software - porosity 0,85 %
22 3 Analysis of the achieved results The measured porosity values of microstructure samples taken from castings in dependence on the increased pressure are given in table 2 and graphically presented in fig. 3. Table 2 Porosity values in dependence on the change of the increased pressure Porosity values in dependence on the change of the increased pressure Sample No. Increased pressure [ MPa ] Die casting plunger velocity [ m.s -1 ] Porosity [ % ] 1.1 13 3,73 2.1 22 2,09 3.1 25 2,6 0,85
3,73 2,09 0,85 0 0,5 1 1,5 2 2,5 3 3,5 4 12 14 16 18 20 22 24 26 incr eased pr essur e [MPa] p o r o s i t y
[ % ]
Fig. 3 Porosity dependence on the change of the increased pressure The microstructure of selected analyzed samples are il- lustrated in figures 4, 5 and 6, where black spots illustrate pores in the casting.
Fig. 4 Microstructure of the sample No 1.1, porosity 3,73%, increased pressure 13 MPa
Fig. 5 Microstructure of the sample No 2.1, porosity 2,09%, increased pressure 22 MPa
Fig. 6 Microstructure of the sample No 3.1, porosity 0,85%, increased pressure 25 MPa In order to prove the achieved results, a non destructive control of castings internal homogeneity was performed the RTG analysis which reliably shows the location, shape and dimensions of internal voids [9, 10]. The analysis of dimensions and a distribution of internal voids enabled to find a connection between the measured mechanical charac- teristics and these parameters. RTG analyses are document- ted on figures 7, 8 and 9. Bright areas show inner cavities in a mould, which arise during the process of mould filling de- pendent on technological casting variables. The analyses showed that the values of porosity correlated with the size of voids which weakened the casting cross section.
Fig. 7 RTG image of the specimen No 1.1, increased pressure 13 MPa
Fig. 8 RTG image of the specimen No 2.1, increased pressure 22 MPa
Fig. 9 RTG image of the specimen No 3.1, increased pressure 25 MPa 4 Conclusions The measured values of porosity presented in table 2 show the substantial differences in dependence on pressure. Based on macroscopic and RTG analysis, the minimum porosity rate was achieved when the increase pressure value
23 was at its peak. There is a tendency in the porosity rate increase when the increase pressure value decreases. Hence increase pressure force heightens mechanical attributes and distinctively decreases porosity by porous pressure volume. At present time, increase pressure is the most discussed factor of die casting. On the hand, increase pressure decree- ases the life cycle of moulds, and on the other, it increases casts replenishment and decreases the volume of closed air in casting. Consequently, increase pressure increases quail- tative characteristic of mould, as well as an increase in ef- fectiveness of production with respect to positive results in economic spheres.
Gaspar Stefan, M.Sc., PhD., Assoc. Prof. Pasko Jan, M.Sc., PhD., Technical University of Kosice Faculty of Manufacturing Technologies Presov Department of Technical Devices Design Sturova Street No. 31, 080 01 Presov, Phone: 051/772 3796, kl. 164, E-mail: stefan.gaspar@tuke.sk, jan.pasko@tuke.sk, Assoc. Prof. Malik Jozef, M.Sc., PhD., Technical University of Kosice Faculty of Metallurgy, Department of Ferrous and Foundry Metallurgy, Park Komenskeho 14, 040 01 Koice, Phone: 055/602 3140, E-mail: jozef.malik@tuke.sk, Slovak Republic
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