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The Effect of Intensification Pressure on the Microstructure of Non-Heat Treated HPDC AlSi9MnVZr Alloy

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Abstract:

The microstructural characteristics of externally solidified crystals (ESCs) and porosities in a non-heat-treated high-pressure die-cast AlSi9MnVZr alloy are investigated under two distinct process conditions: one with the application of lower intensification pressure and the other with higher intensification pressure. Optical microscopy (OM), scanning electron microscopy (SEM), and computed tomography (CT) are employed to analyze the ESCs and porosity distribution. The alloy's microstructure primarily consists of primary α-Al, ESCs, Al-Si eutectic, and iron-rich phases. ESCs nucleate in the shot sleeve, while α-Al forms within the die cavity. When the lower intensification pressure is applied, larger dendritic ESCs are observed, along with significant gas porosity, shrinkage pores, and numerous smaller dispersed pores, resulting in a high porosity fraction. Conversely, the application of higher intensification pressure results in a notable refinement in ESCs morphology, with a significant reduction in their diameter and area fraction. Additionally, the size and fraction of porosity decrease substantially, indicating a marked improvement in casting quality.

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Periodical:

Materials Science Forum (Volume 1175)

Pages:

63-68

DOI:

https://doi.org/10.4028/p-1SGdJf

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Online since:

January 2026

Authors:

Saria Akhtar*, Shou Mei Xiong

Keywords:

Al-Si Alloy, ESCs, High-Pressure Die-Cast, Intensification Pressure, Porosity

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© 2026 Trans Tech Publications Ltd. All Rights Reserved

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* - Corresponding Author

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