Aluminium Pressure Die Casting

In pressure
die casting, die temperature, molten metal pouring temperature, injection pressure and speed
are optimised for a special casting.
Metal for a single shot is loaded into a cylindrical chamber through a pouring aperture. A
piston then forces the metal into the die, the entire operation being completed in a few
seconds, so that iron contamination is virtually eliminated. Using this technique much higher
injection pressure in the range of 70140 Mpa is feasible, enabling lower metal to be
employed and greater intricacy achieved. The castings are less prone to entrapped air and a
higher standard of soundness ensures from the smaller amount of liquid and solidification
shrinkage occurring within the die.
In cold chamber operations the molten metals is usually maintained at constant temperature
in an adjacent holding furnace, where transfer of successive shots to the machine chambers
can be accomplished manually. Holding furnaces may be electrically heated types or the one
using immersion heating types or the one using immersion heating device, which has a close
control over the molten metal.
The molten metal is degassed by chlorine or hexachloroethane followed by modification
with suitable modifier. For thinner sections the working temperature of the molten metal
should be 680 deg. C to 690 deg C and for thicker sections this should be between 650 deg. C
to 680 deg C.
The die temperature should be maintained so that castings of good quality are produced.

Structure of the EN AC-AlSi9Cu3(Fe) aluminium alloy, high pressure cast alloy, light microscope

Oxide cross-sections of anodic layer generated on theENAC-AlSi9Cu3(Fe) alloy, high pressure cast alloy, light microscope

structure of theEN AC-AlSi12(b) alloy, sand cast alloy, light microscopeFig

Structure of theEN AC-AlSi9Cu3(Fe) alloy, sand cast alloy, light microscope

Oxide cross-sections of anodic layer generated on theENAC-AlSi12(b) alloy, sand cast alloy, light microscopeFig

Oxide cross-sections of anodic layer generated on theENAC-AlSi9Cu3(Fe) alloy, sand cast alloy

Structure of theEN AC-AlSi12(b) alloy, high pressure cast alloy, light microscope

Oxide cross-sections of anodic layer generated on the EN AC-AlSi12(b) alloy, high pressure cast alloy, light microscope

furnace
atmosphere should be slightly
reducing, and maximum temperature
should be controlled.
Zinc
chloride / Ammonium Chloride is useful
for cleaning. It separates the metal
from the dross by changing the
interfacial energy.
Melting crucible
Graphite, SiC crucibles or Cast
Iron pots (coated with a thin layer of
refractory powder with sodium silicate
mixed with water as a binder) are used
for melting. Fuel economy is good with
Cast Iron pots, but efficient lining is
needed to avoid excessive
contamination of the melt with Fe.
Reworking of coating at regular interval
and prior drying is a must, as loose
oxide pieces or moisture may affect
the melt.
Temperature control is
essential in aluminium alloy melting.
If the dross formed by adding flux is
allowed to come in contact with air, at
temperature above 9500 C, a strong

crystalline aggregate of corundum is

formed. Its specific gravity of 3.9 gm/
cc is higher than that of Al, hence it
settle down, exposing new melt
surface to further oxidation losses and
hydrogen pick-up. Presence of Alkali
(Na, Ca, Sr, Li) of rare earth elements
like Ce or Be reduces oxidation
tendency even at higher temperature
(if sufficient content in the melt). This
is because high temperature leads to
loss of these elements.
Dross formation (combination
of Al2O3 &other oxides is beneficial to
some extent as it prevents diffusion
of hydrogen into the melt during
melting. On the other hand, it indicates
loss of alloying elements, which
necessitates remelting with flux to
recover the same.
Deoxidation & degassing
Fluxes are used to combine
with oxygen and oxides on melt
surface, enabling recovery of base
metal with alloying elements, making
viscous slag and protecting the melt
from further oxidation attack.
Therefore to homogenize the melt
stirring from bottom upwards, without
excessively disturbing the surface,
should be followed. Fluxes are a must
when excessive proportion of foundry
scrap is used in the charge. Foundries
operating fast-melting crucible
furnaces rarely use fluxes to minimize
the danger from contamination.
Fluxing at low temperature is
desirable to form oxide layer. As once
corundum (crystalline aggregate) is
formed at high temperature, it would
be very difficult to decompose it and
recover base elements.
Proper degassing will
eliminate the chances for occurrence
of defects due to gaseous elements.
In melting Aluminium alloys C2 Cl6
(Hexachloroethane) tablets were
preferred over chlorine gas. At present
use of SF6 (Sulfur hexafluoride) with
carrier gas has become popular. It is
better than earlier practice as it does
not cause damage to environment.
C2Cl6 not only degasses the melt, but
also refines the grains (heterogeneous

nucleation). Gas flushing is more

effective than salt addition for
degassing since chloride salts need
time to decompose, liberate Chlorine
and then remove hydrogen. It may
introduce gas rather than removing it,
if it is not properly dried.
Inclusions (oxides, carbides,
graphite flakes or borides introduced
by grain refiners) are dangerous in
aluminium castings, especially under
fatigue load. Crack initiation,
propagation and failure are steps
involved in fatigue failure which is
favoured by surface irregularities or
cracks. These inclusions affect surface
appearance and also act as nucleating
site for cracks. Proper skimming action
before pouring, use of tea-spout ladle
for pouring, use of strainer core, skim
bob gating or filter usuage are
followed.