Effect of high pressure die casting on the castability, defects and mechanical properties of aluminium alloys in extra-large thin-wall castings

The manufacturing of extra-large thin-wall castings using high pressure die casting is one the most significant challenges for structural applications requiring excellent ductility. present study aims to understand effect process parameters on castability, defect formation and mechanical properties aluminium alloys in with a maximum flow length 1230 mm 2.8 thick channel. Numerical simulation experimental verification were carried out tailor casting. It found that can significantly affect castability as-cast components. For complete casting, yield strength slightly increased but elongation decreased at locations further away from runners. A new concept effective (EFL) proposed used assess castings. Under optimum condition, EFL reach 525 mm, which ratio wall thickness 187 are greater than 120 MPa 10%, respectively. Although be geometrically filled under several conditions, heterogeneity concern, variation overwhelmingly important ductility conditions. Therefore, criteria quality should consider both geometrical soundness homogeneity body.