Hans Ivar Laukli

Grain size distribution in a complex AM60 magnesium alloy die casting

Presolidified equiaxed dendritic crystals are observed in magnesium cold chamber high pressure die castings. Depending on the rate at which new crystals are formed and to what extent they survive in the shot sleeve, a mixture of liquid and crystals is injected into the die cavity resulting in floating crystals in the casting. Box shaped die castings of the AM60 magnesium alloy have been made with a cold chamber high pressure die casting machine. The resulting microstructure is generally observed to consist of (a) a fine grained structure or (b) a mixture of fine grains and coarse grains which is either centred or dispersed in the through thickness cross-section. The prevalence of structures is observed to vary with position in the casting. Close to the gate a coarse grained microstructure dominates, while fine grains dominate further from the gate. The volume fraction of floating crystals in the casting is shown to depend on the initial superheat of the melt. IJCMR/492

Effects of grain refiner additions on the grain structures in HPDC A356 castings

Abstract In the cold chamber high pressure die casting process (HPDC) solidification begins when the metal is poured into the shot sleeve and impinges on the relatively cold shot sleeve wall and plunger. Therefore, a mixture of liquid and externally solidified crystals (ESCs) is injected into the die cavity. The mechanisms that control the formation of ESCs are not fully understood. In the work presented here, the microstructures of thin walled A356 aluminium alloy die castings have been investigated. The castings were produced by varying the melt superheat and constitutional conditions. It was found that the area fraction of ESCs (f sESC) increases when decreasing the melt superheat; a low superheat generates coarser, more globular ESCs, whilst a larger superheat results in branched, dendritic crystals; additions of Ti in solution increase the f sESC and additions of Al–5Ti–1B grain refiner increase the number of globular, coarse ESCs and generate a finer grain size in the casting. The results are discussed with special emphasis on the shot sleeve solidification conditions and the mechanisms that control the formation of the ESCs.

Die Casting of Magnesium Alloys - The Importance of Controlling Die Filling and Solidification

High pressure die casting is characterised by rapid die filling and subsequent rapid cooling and solidification of the metal in the die. These characteristics are favourable for the mechanical properties of magnesium die casting alloys. Since the filling pattern and the cooling rate of the metal is highly dependent on both process parameters and geometry of the part, there is a natural variation in mechanical properties. Variations in filling pattern can be caused by differences in the filling conditions setup by the gating system, pre-solidification in the shot sleeve and during filling as well as variations in the timing of the pressure intensification. In the present work the effects of solidification during filling are discussed with emphasis on the resulting microstructures and the correlation with mechanical properties.

The Influence of Intensification Pressure on the Gate Microstructure of AlSi3MgMn High Pressure Die Castings

This article focuses on the influence of intensification pressure (I.P.) on the feeding through the gate during high pressure die casting (HPDC). Two values of intensification pressure, the lowest and highest possible for the HPDC machine used, were applied to cast AlSi3MgMn tensile-bar specimens. The castings produced with higher I.P. contained a lower total fraction of porosity, as expected. Microstructural characterisation of the gate region showed markedly different features in and adjacent to the gate at the two levels of I.P. used. The microstructures indicate a change in feeding mechanism with increasing I.P. At high I.P. shear band-like features exist through the gate, suggesting that strain localisation in the gate is involved in the feeding of solidification shrinkage during the I.P. stage. At low I.P. such shear bands were not observed in the gates and feeding was less effective, resulting in a higher level of porosity in the HPDC parts.

The Influence of External Mechanical Stresses on Agglomeration and Bending of Solidifying Crystals

The influence of external mechanical stresses on agglomeration and bending of solidifying crystals has been investigated by microstructural characterisation of hypoeutectic Al cast specimens. The samples were produced by near-static cooling, gravity die casting and high pressure die casting (HPDC), where the solidifying crystals experience different levels of mechanical stresses. Electron backscatter diffraction (EBSD) technique was used to acquire grain misorientation data which can be linked to crystal agglomeration and bending behaviour during solidification. The length fraction of low-energy grain boundaries in HPDC samples was substantially higher than in gravity diecast and ‘statically cooled’ samples. This is related to the high amount of shear applied on the solidifying alloy, which promotes crystal collisions and agglomeration. In-grain misorientations were significant only in branched dendritic crystals which were subjected to significant shear stresses. This is attributed to the increased bending moment acting on long, protruding dendrite arms compared to more compact crystal morphologies.