Interdependence between Cooling Rate, Microstructure and Porosity in Mg Alloy Ae42

Porosity is a major concern in the production of light metal parts. This work aims to identify some of the mechanisms of microporosity formation during the gravity-poured castings of magnesium alloy AE42. Two graphite plate molds and a ceramic cylindrical mold were selected to produce a wide range of cooling rates. Temperature data during cooling was acquired with type K thermocouples at 60 Hz at two or three locations of each casting. The microstructure of samples extracted from the regions of measured temperature was then characterized with optical metallography. The results of this study revealed the existence of oxide film defects, similar to those observed in aluminum alloys. The cooling rates showed significant effect on the formation of porosity.