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Experimental and numerical simulation study of porosity on high-pressure aluminum die casting process

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Abstract

The resulting porosity is responsible to 70% of failures on the high-pressure aluminum die casting process. The determination of the origin and setting the pore elimination is a complex mechanism. There are several factors that induce their occurrence. Thus, it is common to employ process and engineering alternatives to try to solve the issue. Faced with such complexity we tried to understand how to apply the finite element methods to minimize the occurrence of pores in high-pressure die casting products. The objective of this study was to develop a methodology to generate an equation that represents the porosity behavior aiming to determine the best engineering and process settings to reduce the pore volume in aluminum injected products. The aim of this study was to develop a methodology to generate an equation that represents the porosity behavior. To do that, the results obtained with the variation of some boundary conditions which were applied to computer simulations in commercial dedicated software were analyzed. It was observed that a flow and solidification analysis of the product in the mold can determine the probability of occurrence of pores in the product already during injection process.

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Abbreviations

ASTM:

American society for testing material

CAD:

Computer aided design

CAE:

Computer aided engineering

HPDC:

High-pressure die casting

FEM:

Finite element method

nadca:

North American die casting association

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Acknowledgements

This research was supported by Federal University of Paraná (UFPR). The authors gratefully extend their gratitude to Metalkraft injection Ltda for the numerical simulations in Magma software, Metallurgical Starcast Ltda by providing the mold and the injection of the test samples and Alumec Industry Ltda by the of X-ray analysis.

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Authors and Affiliations

  1. Fabrica Brasileira de Moldes LTDAFBM, Joinville, Brazil

    D. Concer

  2. Departamento de Engenharia Mecânica, PGMEC Universidade Federal do Paraná, Curitiba, PR, Brazil

    D. Concer & P. V. P. Marcondes

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  1. D. Concer
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  2. P. V. P. Marcondes
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Correspondence to P. V. P. Marcondes.

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Technical Editor: Márcio Bacci da Silva.

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Concer, D., Marcondes, P.V.P. Experimental and numerical simulation study of porosity on high-pressure aluminum die casting process. J Braz. Soc. Mech. Sci. Eng. 39, 3079–3088 (2017). https://doi.org/10.1007/s40430-016-0672-x

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  • DOI: https://doi.org/10.1007/s40430-016-0672-x

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