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Meeting 2022 TMS Annual Meeting & Exhibition
Symposium Defects and Properties of Cast Metals IV
Presentation Title Porosity Formation in High Pressure Die Casting: Experiments and Simulations
Author(s) Nicole Trometer, Xuejun Huang, Michael Moodispaw, Jianyue Zhang, Alan A. Luo
On-Site Speaker (Planned) Alan A. Luo
Abstract Scope Porosity formation in high pressure die casting (HPDC) of aluminum and magnesium alloys is very complex, and is related to many factors such as entrapped air, dissolved gases and alloy shrinkage during solidification. This talk will present our recent experimental and computational investigations of porosity formation during HPDC. Water analog experiments were conducted to validate the effect of vacuum on flow and air entrainment, and compared to process simulation by ProCAST. A three-dimensional cellular automaton was developed to predict solidification microstructure and microporosity evolution during casting. HPDC experiments were carried out on two aluminum alloys at three vacuum levels. The porosity in HPDC samples was characterized using metallography, density measurements, computed tomography (CT) and micro-CT scanning. The decrease in porosity in vacuum die casting was in agreement with simulations. Finally, the porosity was related to the mechanical properties of die cast alloys in various vacuum levels.
Proceedings Inclusion? Planned:
Keywords Solidification, Aluminum, ICME

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

3D Characterization of Competitive Dendrite Growth and On the Role of Low Angle Grain Boundaries during Solidification of Single Crystal Ni-based Superalloys
Characterization of Second Phase Particles in Twin Roll Cast Aluminum Alloy AA 8011
Controlling Freckle Defect Formation Using Magnetic Fields
Elucidating the Relationship between Arc Behavior and Solidification Defects during Vacuum Arc Remelting of Superalloys
F-26: Correlation between Purification Effect and Surface Segregation of Impurities in Aluminium at High Temperatures
F-27: Modeling the Bonding and Structure of Non-metallic Inclusions within a Nickel Matrix during Forging
F-28: The Mechanical Properties and Microstructural of Cast Zinc though Aluminum Inoculation by Ultrasonic Treatment
Formation Mechanisms of Surface Blistering in AA6xxx Rolled Products: Microstructure Characterization, Ultrasonic Analysis, and Rolling Tests
Hybrid Additive Manufacturing of Island Grain Bicrystals
Improving Material Properties Using Contactless Ultrasonic Cavitation
Measurement and Simulation of Reoxidation Inclusions in Steel Casting
Modelling Concurrent Structural Mechanical Mechanisms in Microstructure Solidification
Modification of Cast and Wrought Aluminum Parts Using Hybrid Laser Hot-wire Manufacturing
NOW ON-DEMAND ONLY – Understanding Effects of Oxide Bifilms on Solidification Microstructures by Multiscale Modeling
Nucleation in Undercooled Melt upon Changes in the Electromagnetic Stirring
Particle Capture Defects in Continuous Steel Casting
Porosity Defects in High Pressure Die Castings: Mechanisms and Uncertainties
Porosity Formation in High Pressure Die Casting: Experiments and Simulations
Probabilistic Multiscale Finite Element Model for Predicting Strength and Fracture Strain of Cast Al-Si-Mg Alloy
Quantifying Pore Evolution during Laser Powder Fusion Using High-speed X-ray Imaging and High Fidelity Multiphase Simulation
Reduced-Order Multiscale Modeling of Elasto-Plastic Cast Alloys with Process-Induced Porosity
Research Progress of Composite Preparation Technology of Bimetallic Wire
The Influence of Environmental and Material Properties Data on Defect Predictions in Computational Fluid Dynamics Simulations of Investment Casting
Uncertainty Quantification of Model Predictions due to Fluid Flow in Laser Powder Bed Fusion of IN625

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