Skip to main content
SpringerLink
Log in

Microstructure Formation in AlSi4MgMn and AlMg5Si2Mn High-Pressure Die Castings

  • Published:
Metallurgical and Materials Transactions A Aims and scope Submit manuscript

Abstract

Understanding microstructure formation during high-pressure die casting (HPDC) is important for the effective quality control of high-pressure diecast aluminum-alloy components for high-integrity applications. In this study, two HPDC-specific aluminum alloys, AlSi4MgMn and AlMg5Si2Mn, were cast into tensile test bars by cold-chamber (CC) HPDC. The microstructures of the tensile bar specimens were characterized at different length scales, from the scale of the casting to the scale of the eutectic interlamellar spacing. The results show that the salient as-cast microstructural features, e.g., externally solidified crystals (ESCs), defect bands, the surface layer, grain size distribution, porosity, and hot tears were similar for both alloys. The formation of these features can be understood by considering the influence of flow and solidification during each stage of the HPDC process.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

Notes

  1. Bühler is a trademark of Bühler Druckguss AG, Uzwil, Switzerland.

  2. Gatan is a trademark of Gatan Inc., Pleasanton, CA.

  3. JEOL is a trademark of Japan Electron Optics Ltd., Tokyo.

  4. Thermo-Calc is a trademark of Thermo-Calc Software, Stockholm, Sweden.

  5. Thermotech is a trademark of Thermotech Ltd., Guildford, UK.

References

  1. S. Brusethaug and J.S. Maeland: Cast. Plant Technol. Int., 2004, vol. 20 (4), pp. 16–23.

    Google Scholar 

  2. J.L. Jorstad: Die Cast. Eng., 2008, vol. 52 (5), pp. 18–20.

    Google Scholar 

  3. C. Dorum, H.I. Laukli, O.S. Hopperstad, and M. Langseth: Eur. J. Mech. A: Solids, 2009, vol. 28 (1), pp. 1–13.

    Article  ADS  Google Scholar 

  4. H. Koch, U. Hielscher, H. Sternau, and A.J. Franke: in Silafont-36: The New Low-Iron High-Pressure Die-Casting Alloy, J. Evans, ed., TMS, Warrendale, PA, 1995, pp. 1011–18.

    Google Scholar 

  5. U. Hielscher, H. Sternau, H. Koch, and A.J. Franke: in Magsimal-59: An AlMgMnSi-Type Squeeze-Casting Alloy Designed for Temper F, W. Hale, ed., TMS, Warrendale, PA, 1996, pp. 933–37.

    Google Scholar 

  6. K. Greven and D. Dragulin: Ductile High Pressure Die Casting—Heat Treated or Temper F?, Proc. 2nd Int. Light Met. Technol. Conf., St. Wolfgang, Austria, H. Kaufmann, ed., ARC Leichtmetallkompetenzzentrum Ranshofen GmbH, Ranshofen, Austria, 2005, pp. 221–25.

  7. M.R. Ghomashchi: J. Mater. Process. Technol., 1995, vol. 52 (2–4), pp. 193–206.

    Article  Google Scholar 

  8. X.P. Niu, K.K. Tong, B.H. Hu, and I. Pinwill: Int. J. Cast Met. Res., 1998, vol. 11, pp. 105–12.

    CAS  Google Scholar 

  9. Z.W. Chen: Mater. Sci. Eng. A, 2003, vol. 348 (1–2), pp. 145–53.

    Google Scholar 

  10. M.R. Ghomashchi and G.A. Chadwick: Met. Mater., 1986, vol. 2, pp. 477–81.

    Google Scholar 

  11. M.M. Avedesian and H. Baker: Magnesium and Magnesium Alloys, ASM INTERNATIONAL, Materials Park, OH, 1999, p. 66.

    Google Scholar 

  12. P. Beeley: Foundry Technology, Butterworth-Heinemann, Oxford, United Kingdom, 2001, p. 598.

    Google Scholar 

  13. R.N. Lumley, R.G. Odonnell, D.R. Gunasegaram, and M. Givord: Metall. Mater. Trans. A, 2007, vol. 38A (10), pp. 2564–74.

    Article  ADS  CAS  Google Scholar 

  14. F. Cosse, J.J. Perrier, J.S. Iversen, and S. Brusethaug: in Aluminium P, AS NH, eds., Pechiney Aluminium and Norsk Hydro AS, High Ductility Aluminum Alloy for Die Casting, France, 2003, Patent No. WO03006698.

  15. R. Franke, D. Dragulin, A. Zovi, and F. Casarotto: Metall. Ital., 2007, May, pp. 21–25.

  16. “ASTM B557M-06: Standard Test Methods for Tension Testing Wrought and Cast Aluminum- and Magnesium-Alloy Products (Metric),” Annual Book of ASTM Standards, ASTM International, West Conshohocken, Philadelphia, PA, 2007, vol. 02.02, pp. 441–55.

  17. H.I. Laukli, O. Lohne S. Sannes, H. Gjestland, and L. Arnberg: Int. J. Cast Met. Res., 2003, vol. 16 (6), pp. 515–21.

    CAS  Google Scholar 

  18. A.L. Bowles, K. Nogita, M. Dargusch, C. Davidson, and J. Griffiths: Mater. Trans., 2004, vol. 45 (11), pp. 3114–19.

    Article  CAS  Google Scholar 

  19. H.I. Laukli, L. Arnberg, and O. Lohne: Int. J. Cast Met. Res., 2005, vol. 18 (2), pp. 65–72.

    Article  CAS  Google Scholar 

  20. S. Sannes and H. Westengen: Proc. Int. Conf. Magnesium Alloys and Their Applications, B.L. Mordike and K.U. Kainer, eds., Frankfurt DGM, Germany, Werkstoff Informationsgesellschaft, Frankfurt, Germany, 1998, pp. 223–28.

  21. S.R. Agnew, K.C. Liu, E.A. Kenik, and S. Viswanathan: in Magnesium Technology 2000, H.I. Kaplan, J. Hyrn, and B. Clow, eds., TMS, Warrendale, PA, 2000, pp. 285–90.

    Google Scholar 

  22. P.D.D. Rodrigo and V. Ahuja: Proc. 2nd Israeli Conf. on Magnesium Sci. Technol., Dead Sea, Israel, E. Aghion and D. Eliezer, eds., Magnesium Research Institute, Israel, 2000, pp. 97–104.

  23. A.L. Bowles, J.R. Griffiths, and C.J. Davidson: in Magnesium Technology, J. Hyrn, ed., TMS, Warrendale, PA, 2001, pp. 161–73.

    Google Scholar 

  24. C. Pitsaris, T. Abbott, and C.J. Davidson: Proc. 1st Int. Light Metal Technology Conf., A.K. Dahle, ed., CAST CRC, Brisbane, Australia, 2003, pp. 223–61.

  25. H. Cao and M. Wessén: Int. J. Cast Met. Res., 2005, vol. 18 (6), pp. 377–84.

    Article  CAS  Google Scholar 

  26. H.I. Laukli, C.M. Gourlay, A.K. Dahle, and O. Lohne: Mater. Sci. Eng. A, 2005, vols. 413–414, pp. 92–97.

    Google Scholar 

  27. Z. Fan, G. Liu, and Y. Wang: J. Mater. Sci., 2006, vol. 41, pp. 3631–44.

    Article  ADS  CAS  Google Scholar 

  28. C.M. Gourlay, H.I. Laukli, A.K. Dahle: Metall. Mater. Trans. A, 2007, vol. 38 (8), pp. 1833–44.

    Article  Google Scholar 

  29. S. Sannes, H. Gjestland, H. Westengen, H.I. Laukli, and O. Lohne: J. Mater. Manuf., 2003, vol. 112, pp. 1–9.

    Google Scholar 

  30. L. Wang, T. Nguyen, T. Savage, and C.J. Davidson: Int. J. Cast Met. Res., 2003, vol. 16 (4), pp. 409–17.

    CAS  Google Scholar 

  31. H. Gjestland, S. Sannes, J. Svalestuen, and H. Westengen: J. Mater. Manuf., 2005, vol. 114, pp. 67–73.

    Google Scholar 

  32. www.thermocalc.com.

  33. www.thermotech.co.uk.

  34. M. Gershenzon, P.W. Rohan, and M.T. Murray: Trans. 20th Int. Die Casting Congr. Expos., North American Die Casting Association, Wheeling, IL, 1999, pp. 305–15.

    Google Scholar 

  35. H.I. Laukli, C.M. Gourlay, and A.K. Dahle: Metall. Mater. Trans. A, 2005, vol. 36 (3A), pp. 805–18.

    Google Scholar 

  36. N.A. El-Mahallawy, M.A. Taha, E. Pokora, and F. Klein: J. Mater. Process. Technol., 1998, vol. 73, pp. 125–38.

    Article  Google Scholar 

  37. T. Schnorf, J.-P. Gabathuler, and T. Imwinkelried: in Modeling of Casting, Welding, and Advanced Solidification Processes, D.M. Stefanescu, J.A. Warren, M.R. Jolly, and M.J.M. Krane, eds., TMS, Warrendale, PA, 2003, pp. 717–24.

    Google Scholar 

  38. G. Dour, M.S. Dargusch, C.J. Davidson, and A. Nef: J. Mater. Process. Technol., 2005, vol. 169, pp. 223–33.

    Article  CAS  Google Scholar 

  39. C.M. Gourlay and A.K. Dahle: Nature, 2007, vol. 445, pp. 70–73.

    Article  PubMed  ADS  CAS  Google Scholar 

  40. C.M. Gourlay, B. Meylan, A.K. Dahle: Acta Mater., 2008, vol. 56, pp. 3403–13.

    Article  CAS  Google Scholar 

  41. M.C. Flemings: Solidification Processing, McGraw-Hill, New York, NY, 1974, pp. 246–52.

    Google Scholar 

  42. S.G. Lee, G.R. Patel, and A.M. Gokhale: Scripta Mater., 2005, vol. 52, pp. 1063–68.

    Article  CAS  Google Scholar 

  43. C.M. Dinnis, J.A. Taylor, and A.K. Dahle: Scripta Mater., 2005, vol. 53, pp. 955–58.

    Article  CAS  Google Scholar 

  44. D. Stockdale and I. Wilkinson: J. Inst. Met., 1926, vol. 36, pp. 313–24.

    Google Scholar 

  45. G.K. Sigworth: AFS Transactions: The Modification of Al-Si Casting Alloys: Important Practical and Theoretical Aspects, American Foundry Society, Schaumburg, IL, 2008, pp. 115–39.

    Google Scholar 

  46. A. Hamasaiid, G. Dour, M.S. Dargusch, T. Loulou, C. Davidson, and G. Savage: Metall. Mater. Trans. A, 2008, vol. 39A (4), pp. 853–64.

    Article  ADS  CAS  Google Scholar 

  47. S.A. Metz and M.C. Flemings: AFS Trans., 1969, vol. 77, pp. 329–34.

    CAS  Google Scholar 

Download references

Acknowledgments

The authors acknowledge the support from the CAST Cooperative Research Centre and the Australian Research Council’s Centre of Excellence for Design in Light Metals. The authors thank Dr. Y.H. Cho, The University of Queensland, for valuable discussions. One of the authors (SO) gratefully acknowledges the financial support provided by the Royal Thai Government and a Graduate School Research Travel Grant.

Author information

Authors and Affiliations

  1. Materials Engineering, The University of Queensland, Brisbane, QLD, 4072, Australia

    S. Otarawanna (Postgraduate Student, CAST Cooperative Research Centre) & A. K. Dahle (Professor, Australian Research Council’s Centre of Excellence for Design in Light Metals)

  2. Department of Materials, Imperial College, London, SW7 2AZ, United Kingdom

    C. M. Gourlay (Royal Academy of Engineering and EPSRC Research Fellow)

  3. Research and Technology Development, Hydro Aluminium, N-6601, Sunndalsøra, Norway

    H. I. Laukli (Head of Department)

Authors
  1. S. Otarawanna
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. C. M. Gourlay
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. H. I. Laukli
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. A. K. Dahle
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to S. Otarawanna.

Additional information

Manuscript submitted October 21, 2008.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Otarawanna, S., Gourlay, C.M., Laukli, H.I. et al. Microstructure Formation in AlSi4MgMn and AlMg5Si2Mn High-Pressure Die Castings. Metall Mater Trans A 40, 1645–1659 (2009). https://doi.org/10.1007/s11661-009-9841-1

Download citation

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11661-009-9841-1

Keywords

Search

Navigation