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Meeting 2022 TMS Annual Meeting & Exhibition
Symposium Defects and Properties of Cast Metals IV
Presentation Title Porosity defects in High Pressure Die Castings: Mechanisms and Uncertainties
Author(s) Shishira Bhagavath, Zhixuan Gong, Tim Wigger, Saurabh Shah, Shashidhara Marathe, Bita Ghaffari, Mei Li, Shyamprasad Karagadde, Peter D Lee
On-Site Speaker (Planned) Shishira Bhagavath
Abstract Scope Aluminium alloy components produced from high-pressure die casting (HPDC) are used in key automotive components, with strict requirements on their tensile, compressive and fatigue strengths. However, the mechanical properties may be limited by microstructural features such as porosity that form during the late stages of solidification and semi-solid deformation in the HPDC process. In this study, a thermomechanical process simulator and real time synchrotron X-ray imaging was used to capture the microstructural development of semi-solid alloys during injection into a miniature die cavity. Using image analysis and digital volume correlation the complex interaction of semi-solid flow, shear localisation, and defect formation was elucidated. The results were then correlated to industrial HPDC components formed at various pressure conditions using lab-scale X-ray tomography. By quantifying the shape, size and location of the defects and correlating this with the in-situ studies, the nature of the defect forming mechanisms is ascertained.
Proceedings Inclusion? Planned:
Keywords Aluminum, Solidification, Other

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
Analysis of the Causes of the Fluctuation of the Liquid Level in the Mould for High-speed FTSC Thin Slab Continuous Casting
Analysis of the Causes of the Fluctuation of the Liquid Level in the Mould for High-speed FTSC Thin Slab Continuous Casting
Characterization of Second Phase Particles in Twin Roll Cast Aluminum Alloy AA 8011
Controlling Freckle Defect Formation using Magnetic Fields
Correlation between purification effect and surface segregation of impurities in aluminium at high temperatures
Effect of build height on micro-cracking of additively manufactured superalloy RENÉ 108 thin-wall components
Elucidating the relationship between arc behavior and solidification defects during Vacuum Arc Remelting of Superalloys
Evolution of microstructure and mechanical properties of the as-cast 1030B Al sheet during ultrasound-assisted continuous casting
Evolution of physicochemical properties of tundish covering flux in continuous casting process
Experimental investigation and thermodynamic consideration of oxide inclusions formation in Al-Mg alloys
Experimental Research on Dephosphorization of Mn-Si Alloys Based on CaO-CaF2 Slag System
How to prevent porosity defects in steel casting component
Hybrid additive manufacturing of island grain bicrystals
Improving Material Properties using Contactless Ultrasonic Cavitation
Measurement and Simulation of Reoxidation Inclusions in Steel Casting
Microstructure and properties of Al-alloys produced by the counter gravity casting
Modeling the bonding and structure of non-metallic inclusions within a nickel matrix during forging
Modelling Concurrent Structural Mechanical Mechanisms in Microstructure Solidification
Modification of cast and wrought aluminum parts using hybrid laser hot-wire manufacturing
Nucleation in Undercooled Melt upon Changes in the Electromagnetic Stirring
Numerical Modelling of porosity with combined gas and shrinkage effects in HPDC
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
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
The mechanical properties and microstructural of cast zinc though aluminum inoculation by ultrasonic treatment
Uncertainty Quantification of Model Predictions due to Fluid Flow in Laser Powder Bed Fusion of IN625
Understanding effects of oxide bifilms on solidification microstructures by multiscale modeling
Using Inoculation and Solidification Rate Adjustments to Control Intermetallic Distribution in Nickel Gear Bronze
Utilization of Industrial waste as an alternative to silica sand for foundry industries

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