|About this Abstract
||2022 TMS Annual Meeting & Exhibition
||Defects and Properties of Cast Metals IV
||Porosity Defects in High Pressure Die Castings: Mechanisms and Uncertainties
||Shishira Bhagavath, Zhixuan Gong, Tim Wigger, Saurabh Shah, Shashidhara Marathe, Bita Ghaffari, Mei Li, Shyamprasad Karagadde, Peter D Lee
|On-Site Speaker (Planned)
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.
||Aluminum, Solidification, Other