Abstract
High-pressure die casting has been used widely to manufacture a large variety of products with high dimensional accuracy and productivity. Although this process has a considerably lower cycle time than the other metal forming processes, it is not yet optimized, due to the complexity of the process and the number of parameters to be controlled. Hence, the identification of the parameters affecting quality of castings is the current challenge toward efficient and effective production. In their previous work, the authors proposed and validated some novel kinematic parameters of the plunger, which explain and forecast both the static mechanical properties and the internal quality of castings. The present work extends such an approach by including two other meaningful parameters, which describe the effect of upset pressure and temperature on the final outcome. These parameters are here formulated and have been validated by means of a statistically significant sample manufactured with different plunger motion profiles, upset pressures, and temperatures of the melt and die. The quality of the castings was assessed through static mechanical properties and density measurements. As further proof, internal defects were analyzed on the fracture surfaces of some meaningful castings.
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Acknowledgments
The authors thank all the anonymous reviewers for their valuable comments and suggestions to improve the overall quality of this article. They also acknowledge the financial support of the European MUSIC Project (MUlti-layers control & cognitive System to drive metal and plastic production line for Injected Components, No. 314145) and the contribution of the project partners EnginSoft, Saen, Electronics, and GTA (Aalen University). Moreover, the authors are immensely grateful to the following people and acknowledge their contribution to the experimental activity: Professor Lothar Kallien and Dr. Martina Winkler (Foundry Laboratory of Aalen University of Applied Sciences, Aalen, Germany) and Enrico Della Rovere and Giacomo Mazzacavallo (Department of Management and Engineering, University of Padova, Padova, Italy).
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Manuscript submitted April 9, 2016.
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Fiorese, E., Bonollo, F. Simultaneous Effect of Plunger Motion Profile, Pressure, and Temperature on the Quality of High-Pressure Die-Cast Aluminum Alloys. Metall Mater Trans A 47, 6453–6465 (2016). https://doi.org/10.1007/s11661-016-3732-z
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DOI: https://doi.org/10.1007/s11661-016-3732-z