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Defect Band Characteristics in Mg-Al and Al-Si High-Pressure Die Castings

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Abstract

Bands of positive macrosegregation and porosity commonly follow the surface contour of components produced by high-pressure die casting (HPDC). In this article, Al alloy AlSi7Mg and Mg alloys AZ91 and AM60 were cast into tensile test bars using cold-chamber (cc) HPDC. Microstructural characterization revealed that externally solidified crystals (ESCs) are not necessary for defect band formation, and that defect bands can form both near to and relatively far from any surface layer of different microstructure. The defect bands were 140 to 240 μm thick. In addition to defect-band-related macrosegregation, the castings also contained inverse segregation and surface segregation. Defect bands are shown to have the characteristics of the dilatant shear bands reported in past rheology studies, indicating that defect bands form due to strain localization in partially solid material during the HPDC process.

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Acknowledgments

C.M. Gourlay (CMG) thanks Hydro Aluminium and Professor Lars Arnberg, Norwegian University of Science & Technology, for hospitality and support. The authors acknowledge the support of the CAST Cooperative Research Centre. The CAST Centre was established by the Australian Government’s CRC Program. CMG gratefully acknowledges the financial support provided by an International Postgraduate Research Scholarship (IPRS) and a Graduate School Research Travel Award (GSRTA). The authors thank Henrik M. Laukli for dedicating a toy car.

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Authors and Affiliations

  1. CAST CRC and the ARC CoE for Design in Light Metals, Materials Engineering, The University of Queensland, Brisbane, QLD, 4072, Australia

    C.M. Gourlay (Postdoctoral Research Fellow) & A.K. Dahle (Professor)

  2. Hydro Aluminium Metal, Research & Technology Development, N-6601, Sunndalsøra, Norway

    H.I. Laukli (Senior Engineer)

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  1. C.M. Gourlay
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  3. A.K. Dahle
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Correspondence to C.M. Gourlay.

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Manuscript submitted January 9, 2007.

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Gourlay, C., Laukli, H. & Dahle, A. Defect Band Characteristics in Mg-Al and Al-Si High-Pressure Die Castings. Metall Mater Trans A 38, 1833–1844 (2007). https://doi.org/10.1007/s11661-007-9243-1

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