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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


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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
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The Influence of Environmental and Material Properties Data on Defect Predictions in Computational Fluid Dynamics Simulations of Investment Casting
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