Performance evaluation of different air venting methods on high pressure aluminum die casting process

Abstract

In the automotive industry, die casting technology is used in the production of many parts in series. Due to increased customer demands and reliability expectations, tightness properties are dominant in aluminium alloy based cast parts. In order to acquire the tightness property, it is necessary to control the gas porosity at the casting structure. High pressure die casting aluminium alloy products generally contain gas porosity in certain sizes and ratios due to gas compression during high speed injection of molten metal into the die cavity. Proper die design and evacuation of air in the die and also optimized process parameters need a very critical precaution to reduce the gas porosity. Today, various venting, valve, and vacuum systems are used to facilitate the evacuation of die air. The use of venting systems in the process increases both product quality and process efficiency. In this study, the performance of 3D venting system and mechanical valve performance in high pressure aluminium alloy (AlSi10Mg) casting process with cold chamber were compared on MAGMASOFT high pressure die casting simulation program. As a result of the experimental studies of the 3D vents system, the gas porosity and machine shutdown times can be significantly reduced.