Production of Aluminum Alloy Sealing Part by Semi Solid Die Casting Method

Abstract:

High Pressure Die Casting (HPDC) is a widely preferred process for the production of non-ferrous metals with low melting temperatures. It is particularly suitable for close-to-finish and high-volume production of relatively complex shaped parts. Aluminum-Silicon-Copper alloys, which are frequently preferred in this method, find themselves in many sectors ranging from automotive to aviation. With the developing technology, the usage of High Pressure Die Casting technology has increased significantly, produced part types and the number of parts produced on an annual basis has reached remarkable amounts with the shortening of cycle times. In this study, a supra-eutectic silicon valued Aluminum-Silicon-Copper alloy was produced by gas-induced semi-solid die casting method using a cold chamber high pressure die casting machine. The study observed that many casting problems, especially shrinkage gaps and gas porosity, were overcome, while the microstructure of the parts on which the gas induced semi-solid die casting method was applied was preserved. In addition, energy saving is achieved by lowering the temperature of the holding pot, and thermal fatigue cracks that will occur in the mold in the long-term depending on the temperature difference will be delayed and the mold life will increase.

• Periodical: Defect and Diffusion Forum (Volume 417)
• Pages: 17-22
• DOI: https://doi.org/10.4028/p-x4z1nj
• Online since: June 2022
• Authors: Yüsein Ali*, Anıl Akdogan, Ali Serdar Vanlı
• Keywords: Gas Induced Semi-Solid, Gas Induced Superheated Slurry, High Pressure Die Casting, Sealing Part, Supra-Eutectic Aluminum Alloy

References

[1] S. Aksoy, Improvement of Wear Resistance for Air Brake Compressor Head Cylinder Produced by High Pressure Die Casting Method with Etial-140,, M.Sc. thesis, Selçuk University, (2017).

[2] Bonollo, F., Gramegna, N., & Timelli, G. (2015). High-pressure die-casting: contradictions and challenges. Jom, 67(5), 901-908.

DOI: 10.1007/s11837-015-1333-8

[3] Flemings, M. C. (1991). Behavior of metal alloys in the semisolid state. Metallurgical transactions A, 22(5), 957-981.

DOI: 10.1007/bf02661090

[4] Fan, Z. (2002). Semisolid metal processing. International materials reviews, 47(2), 49-85.[5] R.J. Ong, J.T. Dawley and P.G. Clem: submitted to Journal of Materials Research (2003).

[5] Wannasin, J., Janudom, S., Rattanochaikul, T., Canyook, R., Burapa, R., Chucheep, T., & Thanabumrungkul, S. (2010). Research and development of gas induced semi-solid process for industrial applications. Transactions of Nonferrous Metals Society of China, 20, s1010-s1015.

DOI: 10.1016/s1003-6326(10)60622-x

[6] Süslü, Y. B., Acar, M. S., Senol, M., Mutlu, M., & Keles, O. (2018, March). Optimization in novel partial-solid high pressure aluminum die casting by Taguchi method. In TMS Annual Meeting & Exhibition (pp.293-300). Springer, Cham.

DOI: 10.1007/978-3-319-72284-9_40

[7] Abdi, M., & Shabestari, S. G. (2019). Semi-solid slurry casting using gas induced semi-solid technique to enhance the microstructural characteristics of Al-4.3 Cu alloy. In Solid State Phenomena (Vol. 285, pp.253-258). Trans Tech Publications Ltd.

DOI: 10.4028/www.scientific.net/ssp.285.253

[8] Shabestari, S. G., Honarmand, M., & Saghafian, H. (2015). Microstructural evolution of A380 aluminum alloy produced by gas-induced semi-solid technique (GISS). Advances in Materials and Processing Technologies, 1(1-2), 155-163.

DOI: 10.1080/2374068x.2015.1116236