International Journal of Science and Research (IJSR)

ISSN: 2319-7064
SJIF (2022): 7.942

Study of Process Parameters in High Pressure Die

Casting
Amitkumar Advekar1, Y. Arunkumar2, M. S. Srinath3
1
Department of Mechanical Engineering, Malnad College of Engineering, Hassan - 573202. Karnataka (India)
amitkumarsa007[at]gmail.com
2
Department of I & P Engineering, Malnad College of Engineering, Hassan - 573201 (Karnataka), India
arunkumar. belur[at]gmail.com
3
Department of I & P Engineering, Malnad College of Engineering, Hassan - 573201 (Karnataka), India
srinadme[at]gmail.com

Abstract: A study has been carried out for the die casting process parameters in order to achieve the improved quality of high pressure
die casting (HPDC) products, which is the challenge for the small and large scale manufacturers of HPDC products. Aluminum -
Silicon alloys are the most extensively used, Aluminium alloys are widely used in high - pressure die casting (HPDC) of automotive
components. Several process parameters need to be controlled during HPDC in order to obtain sound and reliable castings. . The
objective was to reduce the defects in the components to obtain the good quality castings and increase productivity. The porosity is the
most common defect frequently encountered in aluminium high pressure die castings, which increases the rejection rate and scrap rate
and reduces the productivity. Porosity formation is closely related to die casting process. In this paper the effect of process parameters on
porosity formation in HPDC have been presented.

Keywords: High pressure die casting (HPDC), HPDC products, Process parameters, Improved quality, Quality castings, Productivity,
Casting Defects.

1. Introduction kept to a minimum.7. Costly moulding dies whose

amortization requires long production runs, usually at least
High Pressure Die casting is a type of metal casting process 5000‐10, 000 pieces.
that is characterized by forcing molten metal under high
pressure into a mould cavity. The mould cavity is created In the die casting process, molten metal is pressed into a
using hardened tool steel dies which have been machined steel die. The cavity between the two halves of the die is
into shape and work similar to an injection mould during the filled rapidly due to the high pressure. The high
process. Most die castings are made from non - ferrous pressure‐injection speed makes it possible to cast the melt in
metals, specifically zinc, copper, aluminium, magnesium, thin sections and complex geometric shapes. The metal
lead and tin based alloys. Depending on the type of metal solidifies when heat is transferred from the melt to the die,
being cast, a hot - or cold - chamber machine is used [1]. after which the die is open and the ʺshotʺ is removed. There
are two basic methods of die casting - cold chamber and hot
The casting equipment and the metal dies represent large chamber. For aluminium alloy castings, the cold chamber
capital costs and this tends to limit the process to high method is almost always used.
volume production. Manufacture of parts using die casting is
relatively simple, involving only four main steps, which Cold chamber method:
keeps the incremental cost per item low. It is especially With the cold chamber method, the melt is usually kept
suited for a large quantity of small to medium sized castings, warm in a holding furnace beside the die‐casting machine. A
which is why die casting produces more castings than any filling device transfers the molten metal from the furnace to
other casting process. Die castings are characterized by a the filling chamber of the die‐casting machine. After that,
very good surface finish and dimensional consistency. the machines shot plunger forces the melt into the die [6].
The casting process usually consists of three phases as
High Pressure Die Casting: High Pressure Die Casting shown in Fig 1.1.
(HPDC) is a versatile manufacturing process in which
molten metal is injected with a die casting machine using Phase1. The first phase begins when the filling device have
considerable pressure into a steel mould or die to form transferred the melt to the machines filling chamber. The
products. High pressure die casting is often used for shot plunger then begins to advance with accelerating speed,
aluminium and brass in many industries including plumbing, up to a maximum speed of 0.5 m/s.
automotive and agriculture [2]. The purpose of the plunger relatively low speed is to avoid
mixing air with the melt. The first phase ends when the
Die casting is characterized by: 1. Technologically metal has filled the entire gating system and its leading edge
advanced equipment.2. High productivity.3. Castings with has reached the cavity inside of the mould.
precise dimensions and even surfaces.4. Capability to
produce thin‐walled castings.5. Very little need for Phase2. This phase is usually called the mould‐filling phase,
post‐casting machining.5. Use of finishing agents can be during this the cavity of the die is filled. The shot plunger
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Paper ID: SR22609200329 DOI: 10.21275/SR22609200329 686
 International Journal of Science and Research (IJSR)
ISSN: 2319-7064
SJIF (2022): 7.942
moves relatively fast, between 2‐6 m/s normally, the entire 7) Quick production: Die cast tooling requires minimal
phase takes between 30‐300 milliseconds. maintenance.
8) Versatile design: Die casting can create virtually any
The time must be kept short in order to fill the mould size, part geometry, surface texture or luster.
completely and avoid cold flows. It is important that the 9) Minimal assembly: Assembly features such as studs,
speed of the shot plunger increase from slow to fast exactly drill holes and bosses can be integrated into mould
when the metal reaches the mouth of the mould cavity. The design.
timing of the increase is determined either by measuring the
motion of the plunger, or via a pressure sensor in the 1.1 Defects in High Pressure Die Casting.
machines hydraulic system.
The most common types of defects occurs in high pressure
Phase3. This phase begins when the entire mould cavity is die casting are listed in below table.
filled with molten metal. At that point, the die‐casting
machines hydraulic system encounters powerful resistance Table 2.1: Common types of defects and their causes
because the shot plunger cannot press more metal into the Defects Causes
die. Extra hydraulic power is then activated to force the - Injection pressure too high
Flash
plunger forward a bit further. - Clamp force too low
- Insufficient shot volume
Unfilled
This compensates for the metals shrinkage during - Unfilled sections
sections
- Low pouring temperature
solidification and compresses any air bubbles that may be
- Injection temperature too high
trapped in the melt. The final pressure on the melt is usually Bubbles
- Non - uniform cooling rate
between 400‐1500 bars, the exact level depends on the - Non - uniform cooling rate
requirements for the casting. A high final pressure makes the Hot tearing
- Cooling time too short
casting pressure tight and increases its mechanical Ejector marks - Ejection force too high
performance level; but it also increases the wear on the die
and the die‐casting machine. Many of the above defects are caused by a non - uniform
cooling rate. A variation in the cooling rate can be caused by
non - uniform wall thickness or non - uniform die
temperature [3].

Depending on the location of the casting defects, they can be

divided into two major categories, namely ―Surface‖ and
―Subsurface‖ defects.

Surface Defects:
Surface defects are occurring on the surface or near to the
Figure 1.1: Different phases of die casting with a cold surface (exposed to surface) of the castings.
chamber machine: (a) Moulding die is closed, (b) The short Surface defects in high pressure die castings can result from
plunger forces the melt into the mould, (c) Moulding die is deficiencies at any stage of the manufacturing process.
opened [11]. 1) Flash: The occurrence of molten material seeping out
of the mould cavity and solidifying.
In the Fig 1.1 (a) Moulding die is closed. The melt is poured 2) Unfilled sections (Misrun):
into the filling chamber (often called cold chamber), in Fig
1.1 (b) The short plunger forces the melt into the mould This is usually caused by the metal solidifying before it fills
cavity at high speed and pressure. The melt is also kept the cavity.
under pressure during solidification, and in Fig 1.1 (c) When a) The metal was too cold.
the melt has solidified, the moulding die is opened and the b) It could be too small a sprue, gate.
casting is forced out of the movable die half by ejector pins. c) Insufficient shot volume.
d) Slow injection.
Advantages of the Die Casting e) Low pouring temperature.
Typical advantages of die casting process include
1) Excellent dimensional accuracy. 1) Hot Tearing:
2) The smooth surfaces of Product. A part defect, sometimes called hot cracking, which
3) Casted parts require no machining except the removal describes cracks that result from shrinkage. If a part is not
of flash around the edge and possible drilling and allowed to shrink freely and encounters an obstruction, the
tapping holes. solidified material will crack. The main causes of problems
4) High pressure die casting production is fast and are Non - uniform cooling rate.
inexpensive relative to other casting processes.
5) High quality: Parts created through die casting deliver a Sub - surface Defects:
long service life. Sub - surface defects are not visible to the naked eye due to
6) High reliability: Uniformity of mass - produced parts is their occurrence below the surface of the castings.
exceptional.

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Paper ID: SR22609200329 DOI: 10.21275/SR22609200329 687
 International Journal of Science and Research (IJSR)
ISSN: 2319-7064
SJIF (2022): 7.942
2) Non - metallic inclusions:
Inclusions occur as varying types with differing sizes and
shapes.
a) Aluminium oxides are of different crystallographic or
amorphous forms as films, flakes, and agglomerated
particles.
b) Magnesium oxide is typically present as fine particulate.
c) Spinals can be small hard nodules or large complex
shapes. Figure 3.1: Flash
d) Refractory and other exogenous inclusions may be
identified by their appearance and composition. Flash can be described as any unwanted, excess metal which
comes out of the die attached to the cavity or runner.
3) Shrinkage and Porosity defects: Typically it forms a thin sheet of metal at the parting faces.
Porosity and Shrinkage is the formation of voids inside the
castings either through the entrapment of gas, improper There are a number of different causes of flash, and the
pressure configuration in HPDC machines and improper amount and severity can vary from a minor inconvenience to
Solidification of material. a major quality issue.
The problem can be divided into three major types: At the very least, flash is waste material, which mainly turns
 Gas porosity: The gas porosity is the porosity in casting into dross when re - melted, and therefore is a hidden cost to
due to the presence of gas. the business.
 Shrinkage porosity: The shrinkage porosity is due to
shrinking of metal, so that the metal loses volume and Flash is often accompanied by an increase in the thickness of
hence more metal is required to fill the gaps (voids) the whole casting. This adds mass to the part (and therefore
produced. increases metal cost) and increases its dimensions. Critical
 Flow porosity: Melt related porosity formation because dimensions across parting lines can end up over top
hydrogen entrapment in HPDC is not a big problem. tolerance, leading to costly rejects.
Hydrogen can be considered seriously if the scrap is re -
melted. Some of the causes of flash are:
1. Damage to die faces and die components.2. Parts of the
Applications of Die Casting Process: die have insufficient strength.3. Bending, crowning of
Die - casting is the largest casting technique that is used to stretching of dies.4. Cavities offset from centre of platen.5.
manufacture consumer, commercial and industrial products Insufficient machine clamp - up. Pressure spikes at the end
like of cavity fill.6. Excessive intensification pressure.7.
1. Automobiles.2. Toys.3. Parts of a sink faucet.4. Incorrect intensification timing.8. Damage, or wear, in
Connector housing.5. Gears.6. Most die castings are done toggle mechanisms.9. Machine hydraulic malfunction.10.
from non - ferrous metals like magnesium, aluminium, etc. Hydraulic valve or seal leaks [4].

1.2 Critical Process Parameters in High Pressure Die 1.3 Casting material
Casting.
The four main metal groups used with this technology are
Major process parameters in high pressure die casting aluminum, zinc, magnesium and copper - base alloys.
include [2] High pressure die casting (HPDC) is a high volume
1. Flash. 2. Cast material. 3. Mould material.4. Poring manufacturing process for components of different sizes and
temperature.5. Flow temperature.6. Solidification time.7. shapes and there are some specifics of the process which can
Shrinkage and porosity [3]. be discussed.
In die casting, non - ferrous metals are used to manufacture
1. Flash: Flash or flashing is the material that is left on the components, and the choice of alloy for a particular
casted part due to the ‗seam‘ of the mould. The material application depends on budget, weight and material
enters into the seam of the mould slightly and when removed properties [10].
from the mould leaves a thin wafer of material attached. a) Aluminium: Aluminium is one of the most important
This is common and simple to remove with simple methods. materials with a share of more than 80 %, followed by
Whilst simple to remove and clean, great care must be taken zinc and magnesium. However, copper, lead and tin can
when designing a mould to ensure that the flashing will not also be used. The alloys have different properties. For
interfere with the function (or aesthetics, if important) of the example, aluminium (600°C) and magnesium (520°C)
final product. This can be particularly relevant in parts with have a high melting point, zinc (380°C) and lead
high tolerances, friction fits or areas that require a seal. Our (320°C) a low melting point.
experienced mould designers and tool makers will work with Die casting alloys offer many advantages:
you and your product designers to ensure that any seam lines High corrosion resistance.2. High strength and
are non - obtrusive and hidden. hardness.3. High thermal conductivity.4. High electrical
conductivity.5. Very good EMI/ RFI isolation.6. Good
processing properties.

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ISSN: 2319-7064
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b) Zinc: Zinc plays an important role in the automotive materials cycle. Zinc pressure parts are later used in the
industry. There it is used to manufacture die cast recycling process for example in the form of zinc alloys.
components for vehicles. Zinc die casting is used Due to the closed material cycle, zinc ensures a responsible
wherever safety and maximum stability are required in a and sustainable use of raw materials. Zinc die casting meets
vehicle. Zinc plays an important role in the automotive the strict safety specifications that apply inside and on a
industry. There it is used to manufacture die cast vehicle. That is why belt pretensioners or belt rewinders
components for vehicles. Zinc die casting is used which require strength and functionality in hazardous
wherever safety and maximum stability are required in a situations where life and death are at stake, are made of zinc.
vehicle — often concealed and invisible to the eyes of In addition to safety aspects, the material ensures long
drivers and passengers. Zinc die casting will be service life even under extreme weather or operating
indispensable in the coming decades. The ease of conditions [7].
processing, not only when it comes to large quantities,
will ensures that the quantity used is going to increase a. Magnesium: Magnesium die castings have an enormous
rather than decrease. field of application. Many different engineering disciplines
benefit from the special material properties of this
High - Tech Products Made from Zinc Die Casting. nonferrous metal. Magnesium is one of the lightest and most
The market for car parts made of die cast zinc is highly pliable metals used in alloy die casting and machining today.
important for the automotive industry. Its significance will While pure magnesium is too volatile, combustible, and
increase even more with lightweight construction. This is corrosive to be used in its purest form, magnesium can be
because zinc is used to manufacture thin - walled parts combined with other lightweight metals such as aluminum to
which have a narrow scope of tolerance and are very robust. be die cast into almost any shape or texture. These
Zinc die casting is used especially for components where compound materials offer excellent potential for thin - wall
safety is a top priority and the life of the occupants is to be and complex structure formation, making them a leading
protected — for example, the rollers of the seat belt or belt choice for use in projects requiring more delicate work. As it
pretensioners. But housings such as the wiper motor which is commonly considered to be the eight most common
provides a clear view are also made of zinc. Spark plug element in the earth's crust, the cost - to - material ratio also
heads, the housing of many starter motors, the cylinders of makes it an attractive choice for use in bulk machining work
modern door locks and even the door handles rely on zinc. or mass production. It is the lightest alloy (in terms of mass)
commonly cast in modern die moulding.
Car Parts Made of Zinc Die Casting.
In many of the latest car models, parts of the fittings, Magnesium - aluminium alloy products, most commonly
handles, dampers (e. g. ventilation flaps in the interior), the material AZ91D, are used frequently in industrial and
switches and blinds are made of zinc. The advantage of zinc consumer products as EMI and RFI shielding, vehicle parts,
die castings is obvious. The die casting process can and as structural components. However, the metal's high
transform zinc into all kinds of shapes needed by the heat resistance, excellent electrical conductivity, and 100%
automotive industry. Additionally, alternative metals cannot reclamation rate when it is recycled make it extremely
keep up with its surface qualities. The parts maintain narrow versatile. As aluminum shares many of the same properties
tolerances and the surface of products made of zinc die as the light metal it is often favored for use in combined die
casting is smooth. This means that all zinc parts have an casting. However, magnesium can be combined with many
exquisite look and increase the value of high - end cars. other die cast metals.

Zinc Die Casting in the Car: A Sustainable Product. State of Magnesium Die Casting Industry: Magnesium is the
It is right that the automotive industry is increasingly relying lightest of all the engineering metals, having density of 1.74
on the inherent properties of zinc. Its consistent ratio of dead g/cm3. Magnesium is 35% lighter than aluminum and over
weight to material strength makes it possible to reduce the four times lighter than steel. Magnesium alloys reduce
weight of a vehicle. The corrosion protection provided by vibration 25 times better than aluminium, giving this
zinc ensures optimum service life for housings exposed to material a clear advantage by reducing road vibration. Most
the weather, e. g. the housing of wiper motors. But zinc has steering wheels in use today have a magnesium core, over -
more to offer than that: The more important autonomous molded with vinyl, which improves driver comfort by
driving becomes, the more important will parts that protect preventing vibration from reaching the driver‘s hands.
against electromagnetic and electrical influences become. Magnesium is the eighth most common element in nature,
These parts ensure that components that are essential to constitutes about 2 % of the Earth's crust by weight, and is
transmission do not correlate. Not to mention external the third most plentiful element dissolved in seawater (about
influences this must also be shielded. 1.3 kg per cubic meter).

Zinc meets these requirements. And even if it is not feasible It has good ductility, better noise and vibration dampening
to produce the complete part from zinc, it can be applied by than aluminum, and excellent cast - ability. Alloying
thermal spraying. Due to the high cost - effectiveness of zinc magnesium with aluminum, rare earths, zinc, or zirconium
die castings not only in the production of large series, it is to increases its strength to weight ratio, making the alloy very
be expected that the automotive industry will increasingly suitable wherever weight reduction is important, and where
rely on zinc for instance in connectors or housings. it is imperative to reduce inertial forces. The high specific
Furthermore, zinc is a sustainable and resource - efficient strength and stiffness of magnesium are very desirable
material. It can be recycled perfectly and returned to the characteristics in applications wherever the weight of the
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Paper ID: SR22609200329 DOI: 10.21275/SR22609200329 689
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ISSN: 2319-7064
SJIF (2022): 7.942
product is an important feature. Besides having these innate 1.4 Mould material
characteristics, magnesium is also environmentally friendly.
It is easily segregated from the recycling stream and is The mold cavity is created using two hardened tool steel dies
recoverable by re - melting. In addition, even if not recycled, which have been machined into shape and work similarly to
it will naturally dissolve into magnesium oxide, which is an injection mold during the process. Most die castings are
harmless to people and to the environment. made from non - ferrous metals, specifically zinc, copper,
aluminium, magnesium, lead, pewter, and tin - based
b. High Copper Alloys: High Copper Alloys (C81400 - alloys.
C82800). Next in order of decreasing copper content are
alloys with a minimum designated purity of 94% Cu. The When the mould is closed, the melt is pressed into the mold
high copper alloys are used primarily for their unique under a pressure of up to 1, 200 bar, achieving maximum
combination of high strength and good conductivity. Their mold filling speeds of 150 m/s (540 km/h). High closing and
corrosion resistance can be better than that of copper itself. clamping forces are required to press the mold halves
Chromium coppers (C8 1400 and C81500), with a tensile against each other and keep the molds closed: up to 8, 000
strength of 45 ksi (3 10 MPa) and a conductivity of 82% kN (800 t) in hot chamber die casting machines and up to
lACS (see page 86) (as heat treated), are used in electrical 45, 000 kN (4, 500 t) in cold chamber die casting machines.
contacts, clamps, welding gear and similar By using such high forces, large - sized cast parts can be
electromechanical hardware. At more than 160 ksi (1, 100 manufactured. Concerning material and design, the molds
MPa), the beryllium coppers have the highest tensile that are used for this purpose must be designed in such a
strengths of all the copper alloys. They are used in heavy way that they can permanently withstand the loads related to
duty mechanical and electromechanical equipment requiring the large melt quantities. When the metal has solidified, the
ultrahigh strength and good electrical and/or thermal mold halves open and the cast part is ejected by bolts or
conductivity. The high copper alloys' corrosion resistance is removed by a robot and conveyed for further processing.
as good as or better than that of pure copper. It is adequate
for electrical and electronic products used outdoors or in Die cast mold development is a versatile process that
marine environments, which generally do not require enables the production of a large quantity of small to
extraordinary corrosion protection. medium - size castings.

The copper alloy families are based on composition and Mold Manufacturing Processes: Die casting is a
metallurgical structure. These, in turn, influence or are manufacturing process that is commonly used for producing
influenced by the way the metals solidify. Solidification accurately dimensioned, sharply defined, smooth, or
behavior is an important consideration, both in casting textured surface metal parts. It is accomplished by forcing
design and when selecting a casting process. The following molten metal under high pressure into reusable metal dies.
description of the alloys according to their structures and The die casting molds process follows the subsequent
freezing behavior is intended as a brief introduction to a very procedures regarding die cast mold manufacturing:
complex subject. Coppers are metallurgically simple a) A mold is created in at least two sections to allow the
materials, containing a single face - cantered cubic alpha proper removal of the casting.
phase. Coppers solidify at a fixed temperature, 1, 981°F (1, b) The sections are mounted securely within the machine
083°C), but there is usually some undercooling. Freezing and are arranged so that one is stationary while the other
begins as a thin chill zone at the mold wall, then follows the is moveable.
freezing point isotherm inward until the entire body has c) The two are tightly clamped together.
solidified. Cast structures exhibit columnar grain structures d) Molten metal is injected into the die cavity where it
oriented perpendicular to the solidification front. Centerline quickly solidifies.
shrinkage cavities can fonn at isolated "hot spots" and e) The die halves are drawn apart and the casting is ejected.
inadequately fed regions of the casting; this must be taken
into account when laying out the casting's design. When compared with sand or permanent mould processes,
HPDC (High Pressure Die Casting) is the fastest method in
High Copper Alloys. Like the coppers, the high copper the industry for producing highly precise non - ferrous metal
alloys solidify by skin formation followed by columnar grain parts.
growth. With a few exceptions, the high copper alloys
typically have very narrow freezing ranges and also produce High Pressure Die Casting Mold Benefits
centerline shrinkage in regions that are improperly fed. The There are numerous advantages regarding the usage of die
chromium and beryllium coppers develop maximum casting (or HPDC) process. Some of the advantages and
mechanical properties through age - hardening heat disadvantages of the HPDC moulds process include the
treatments consisting of a solution annealing step followed following:
by quenching and reheating to an appropri ate aging
temperature. Conductivity is highest in the aged (maximum HPDC Mould Advantages:
strength) or slightly overaged (lower strength but higher 1. Net shape part configuration is achievable.2. High
ductility) conditions, i. e., when the hardening element has dimensional accuracy is achievable.3. Fast production.4.
mostly precipitated and the remaining matrix consist of Thinner walls are achievable when compared to investment
nearly pure copper [7]. and sand castings.5. Wide range of possible shapes
external threads can be casted.6. Steel inserts can be over -
molded.7. Holes can be cored to internal tap drill size
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Paper ID: SR22609200329 DOI: 10.21275/SR22609200329 690
 International Journal of Science and Research (IJSR)
ISSN: 2319-7064
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HPDC Mould Disadvantages: parameters that much influence the mechanical properties
a) A relatively large production volume is required to make and casting - ability of aluminium alloys.
the process cost - effective.
b) High initial cost (tool, set up). Similar to melting temperature, the aluminium pouring
c) Minimum wall thickness: 0.040". temperature has to be provided sufficient, not too much, not
d) Maximum wall thickness: 0.200". In some cases, too low to ensure the casting part quality. Adding too high
acceptable up to 0.50". pouring temperature can cause shrinkage, mould wrapping
e) Draft radii and fillets required on the casting. and reduce the dimensional accuracy of the aluminium
f) Potential porosity issue. casting products. On the other hand, the too low aluminium
pouring temperature can result in the mould cavity is not
Die Casting Moulds. fully filled due to the rapid solidification of aluminium
The moulds that are utilized within the die casting mould alloys, causing casting defects and inaccuracy.
design process are constructed from premium, heat -
resistant steel grades. The moulds are halved to form a Additionally, it has been observed that pinholes in
cavity into which the liquid metal is pressed during the aluminium casting parts are formed due to the absorbed
casting process. A die casting mould is so strong over a hydrogen. By providing an adequate pouring temperature to
million parts can generally be created with a single mould. aluminium alloys, it helps to reduce the porosity created
However, the actual life of the mould will solely depend on during the casting process.
the die casting materials that are used.
The aluminium alloy pouring temperature requires being
Advantages of Die Casting Mould Development. higher than the melting point.
Die casting utilizes non - ferrous metals (such as aluminium
alloys or zinc alloys) to manufacture components. The Add extra temperature (superheat) during the aluminium
chosen alloy for an application depends on budget, weight, alloy melting process helps to increase the fluidity,
and material properties. Other benefits associated with the compensate the heat losses before they are in the mould
use of die casting mould design, include: cavity shape, and lower the heat extraction rate by mould. It
1. High thermal conductivity.2. High electrical has observed that the optimal pouring temperature range of
conductivity.3. Good processing properties.4. High aluminium alloys is 680°C to 750°C.
corrosion resistance.5. High strength and hardness.
At this range, the aluminium casting parts are produced with
Quality Die Casting Mould Design Benefits. good mechanical properties and casting quality.
When it comes to high quality die casting mould
development there are several influences that contribute to And the best pouring temperature to aluminium alloys to
the overall success of the process. These factors include the obtain the best surface finish of aluminium casting products
following has to be tested in the range of 680°C – 700°C.
First Class Engineering, die - cast tools design in house.
Manage and oversee all aspects of tooling. At a higher pouring temperature, it will obtain the very
Developing injection process parameters: gate size, location, rough casting surfaces, lower the strength of casting, and
feeding speed, fill time, injection pressure, press size. trap gases causing casting defects such as blow holes. The
1. Parting line, runner, overflows, venting, cooling.2. effects of mould design on aluminium pouring temperature.
Minimum and Maximum wall thickness.3. Choice of the Moreover, the pouring temperature of alloys is also partially
mould material and hardness based on mould forces influenced by the different mould sizes and capacities
calculation.4. Superior or Premium Grade H13.5. Flow relating to the wall thickness of the casting. Accordingly, a
simulation.6. Draft, radii, filets.7. Establishing machining higher pouring temperature is applied for thin wall
stock.8. Utilization of both domestic and overseas tooling aluminium casting parts, whereas, a lower pouring
suppliers. temperature is usually used for thick wall castings or solid
pieces. It recommends that thick - walled casting parts are
Additional Considerations for Die Casting Mould preferred to pour between 620°C while the thin - walled
Design. design should be poured at up to 730°C.
Some of the additional factors that should be considered
before starting a die casting mould development project 1.5 Flow temperature
include the following:
1. Gate calculation, feeding speed and fill time.2. Press size, What is the proper die temperature?
clamping forces calculation.3. Shot sleeve choice and The die temperature will depend on what alloy you intend to
calculation.4. Venting and overflows.5. Establishing cast cast. You want to avoid putting excess strain on your die,
and technological Datum.6. Establishing machining stock. stressing the die will lower the life expectancy of the die
4. Pouring temperature. In order to fill the mold cavity, itself. It is best to pour your alloy into your die when it is
which is usually larger than conventional ones, the pouring approximately 50° to 70° degrees higher than the
temperature needs to be as high as 700°C to prevent crystallization temperature of the alloy. The die needs to be
premature solidification. maintained at approximately a third of the alloy‘s
temperature.
Aluminium pouring temperature, together with the
melting temperature, is the aluminium casting temperature
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Paper ID: SR22609200329 DOI: 10.21275/SR22609200329 691
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ISSN: 2319-7064
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What is the proper die casting chamber/machine 2) The reason for shrinkage porosity:
temperature? a) During the solidification process, the casting cannot be
The temperature required for the die casting machine is a supplemented from the aluminium distributing liquid
complex calculation that includes things such as the alloy and form holes.
type, die type, size of the part to cast, and more. The b) The pouring temperature is too high, and the mould
chamber temperature needs to be determined by an gradient distribution is unreasonable.
experienced die caster. c) The injection ratio is low and the boost pressure is too
low.
What is the proper alloy temperature? d) The inner gate is thin, the area is too small, and it
Alloy temperatures vary greatly depending on the material. solidifies prematurely, which is not conducive to
Here are two examples of the most common die cast alloys – pressure transmission and liquid metal feeding.
aluminium and zinc. e) There are hot spots or cross - sections in the casting
structure that change drastically.
What happens if the temperature is incorrect? f) The amount of molten metal pouring is too small, the
If the temperature of the metal being cast is too hot for the remaining material is too thin, and it cannot be used for
mold it can damage the mold, which dramatically shortens feeding.
the effective usage life of the mold. If the temperature is too
cold the metal will cool too quickly as it is flowing into the 3) How to improve the shrinkage porosity:
mold which can cause defects (such as porosity problems or a) Lower the pouring temperature and reduce the
misruns). shrinkage.
b) Increase the injection pressure and boost pressure to
1.5 Solidification time improve the compactness.
c) Modify the inner gate to make the pressure better,
The solidification time of Aluminium - %Sn alloys in sand which is conducive to the feeding effect of liquid metal.
casting is always greater than the solidification time of d) Change the structure of the castings, eliminate the metal
Aluminium - %Sn alloys in die casting. The major gathering parts, and make the wall thickness as uniform
difference here is that the mold material has a much larger as possible.
thermal conductivity than sand, and so the solidification will e) Speed up the cooling of thick parts.
be much more rapid. In the insulating mold (sand mold) the
rate of transfer in the sand was the rate limiting step. In
permanent molds the rate limiting step is at the interface
between the metal and mold, where heat is transferred
between the solidifying metal and the permanent mold. Also
presence difference between theoretical and experimental
value of solidification time, this difference may be because
the sands with high moisture contents extract heat faster than
sands with low moisture, then lead up to difference between
theoretical and experimental value of solidification time.
The experimental and theoretical value of solidification time
for aluminium - 20%Sn alloy in sand casting is 105.88 sec
Figure 3.2: Shrinkage and porosity defect
and 83 sec respectively. Also the solidification time of
Aluminium - 20%Sn alloy in die is 2.5 sec and 1.77 sec
Porosity In Aluminium Alloy Die Castings.
respectively. While the experimental and theoretical value of
Porosity is a big concern in die casting which includes two
solidification time for aluminium - 40%Sn alloy in sand
basic types: gas porosity and shrinkage. Both can cause
casting is 111.33 sec and 91 sec respectively. While the
costly waste loss and limit the use of die - cast parts in
solidification time of the same alloy is 2.88 sec and 1.98 sec
critical high - strength applications. Each takes a completely
respectively.
different corrective action, however they can look similar. In
this article, we introduce the causes to porosity in aluminium
1.6 Shrinkage and porosity
casting and measures to solve the gas porosity of die
castings & how to reduce the porosity of aluminium casting
Reasons of Shrinkage Porosity of Aluminum Die Casting.
[10].
1) What‘s the shrinkage porosity:
What is Porosity in Die Casting?
Shrinkage and shrinkage porosity usually occur inside the
Porosity is one of the most common die casting defects. This
casting, which is one of the common defects in the
porosity is found when there are small voids, holes or
formation of aluminium alloy die castings. Shrinkage
pockets of air that is found within metal. Porosity is inherent
porosity of aluminium alloy die - castings generally occurs
in die casting manufacturing. Typically, the porosity occurs
in thick parts at the root of the riser near the inner runner,
when air is trapped into the metal by the die casting
wall thickness transition points, and thin walls with large flat
machinery, often leaving gaps at the top of the die or filling
surfaces. The fracture of aluminium castings in the as - cast
a mould too slowly and having some solidification occur too
state is gray, light yellow, and grayish - white, light yellow,
soon. It can also be created when the air used to force
or gray - black after heat treatment.
molten metal into the mould isn‘t completely forced out or
able to escape via vents and overflows. The two most
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Paper ID: SR22609200329 DOI: 10.21275/SR22609200329 692
 International Journal of Science and Research (IJSR)
ISSN: 2319-7064
SJIF (2022): 7.942
common types of casting porosity types are: gas porosity than 60% of the total cross - sectional area of the inner
and shrinkage porosity. gate, otherwise the slag discharge effect will be poor [8].
5) Adding core pulling, cold iron or water cooling or
What Causes Porosity In Aluminum Casting? increasing cool - down rates for the mould should be
In the production of aluminium alloy die casting, people considered when the mould is designed. In the
often call small holes on the product gas porosity in general production of die - casting, attention should be paid to
[10]. There are many causes of gas porosity in aluminium the amount of super cooling in the thick parts, and the
die casing. In summary, aluminium die casting gas porosity pouring temperature should be appropriately decreased
can be divided into the following categories: [8].
 Gas porosity caused by the poor quality of fine wall
degassing. How to Test the Porosity of Aluminum Casting?
 Refining gas porosity caused by poor discharge. For the porosity test of aluminium casting, several positions
 Gas porosity caused by poor exhaust channel of the should be considered: the position of maximum stress in
mould and the poor mould exhaust design structure. finite element analysis, the position of air entrainment in the
 Uneven wall thickness of aluminium alloy discs and simulation analysis of parts, the key parts of parts.
cylinders. Generally, the die castings can be inspected by X - ray. After
 Gas porosity caused by entrainment air due to improper defects are found, the parts are cut for further inspection. In
die casting parameters. process control, ASTM E505 grade 2 controls and ASTM
 Shrinkage porosity of aluminium alloys. E505 grade 1 control shall be adopted for key parts. The
surface of pores is generally smooth, round or oval,
 Gas porosity caused by excessive difference of the
product wall thickness. sometimes isolated, sometimes clustered together. However,
the shape of shrinkage cavity and porosity is irregular, and
the surface colour is dark and not smooth. Dendrite structure
How to Reduce the Porosity of HPDC Casting Process
can be found in the defect position under microscope and
electron microscope.
Take these measures to fix die casting gas porosity:
1) In the process of material selection, we should choose
dry and clean alloy materials to avoid generating too The 5 Types of Aluminium Casting Defects and How to
much water vapour. When melting aluminium alloy, we Treat Them [10].
It‘s not uncommon for defects to arise during the aluminium
must strictly follow the operation procedure and avoid
casting process. Some are so small as to be tolerable, and
entertaining gas as much as possible. Control the melting
some can be easily repaired. Others, though, are so severe
temperature, avoid overheating and select high quality
refining agent or inert gas (such as nitrogen) to ensure that we have no recourse but to throw the casting out and
start again. Of course, this is far from ideal. Fortunately, we
gas removal during aluminium alloy melting process. We
have numerous ways to treat defects. Here are the five main
should select coating that has less volatile gas and ensure
types of irregularities found in aluminium castings [9]:
evaporation under low temperature and evenly apply
coating to prevent the volatilized gas from entering the  Shrinkage – Shrinkage defects occur during the
molten alloy [3]. solidification process. Open shrinkage defects are found
2) The filling speed should not be too high or too low as it‘s on the surface of castings, whereas closed shrinkage
determined according to the die - cast alloy and structural defects are formed within the casting, when isolated
characteristics of the casting. Under the premise of pools of liquid are allowed to form within the solidified
satisfying the casting moulding and the die casting metal.
process conditions permitting, try to reduce the molten  Gas Porosity – Liquid aluminium can hold large
aluminium casting temperature as much as possible volumes of dissolved gas, whereas solid aluminium
during die casting. This can reduce the volume shrinkage cannot. As a result, the gas can form bubbles within the
of the casting, reducing shrinkage holes and shrinkage metal as it cools, reducing the overall strength of the
porosity. casting. Gas porosity is most commonly caused by
3) Vacuum impregnation is a method that seals the dissolved hydrogen in the molten metal.
aluminium alloy die casting resulting from porosity. The  Pouring Metal Defects – A few things can go wrong
impregnating material is introduced into the voids within when pouring molten metal. The liquid metal may not fill
the casting wall thickness through the vacuum and the entire mould cavity, resulting in an unfilled portion.
pressure methods. This method is an economical and Alternatively, two fronts of metal may not fuse properly
effective permanent solution to solve the problem of within the mould cavity, resulting in a weak spot.
aluminium alloy die casting porosity. There is no limit to  Metallurgical Defects – Sometimes, the chemical
the size of castings that can be impregnated. composition of the metal does not allow for optimum
4) For gas porosity caused by poor discharge, we should cooling conditions. This can result in hot spots – hard
improve the exhaust channel of the mould and clean the areas on the surface of the casting that cooled quicker
residual aluminium skin on the mould exhaust channel. than the surrounding metal.
Change the thickness of the gate and the direction of the  Mould Defects – Metal is weaker when it‘s hot. If the
gate, and we can set the overflow and discharge groove mould has been poorly designed, it can cause residual
at the position where the air hole is formed, so that the stresses in the material as it cools, resulting in hot
gas can have a chance to be discharged. The total cross - cracking.
sectional area of the overflow chute should not be less

Volume 11 Issue 6, June 2022

www.ijsr.net
Licensed Under Creative Commons Attribution CC BY
Paper ID: SR22609200329 DOI: 10.21275/SR22609200329 693
 International Journal of Science and Research (IJSR)
ISSN: 2319-7064
SJIF (2022): 7.942
How Do We Treat Casting Defects Review, Vaibhav Ingle. Int. Journal of Engineering
Our approach to treating irregularities in our castings will Research and Application ISSN: 2248 - 9622, Vol.7,
vary depending on the nature of the defect. But as usual, Issue 3, (Part - 3) March 2017, pp.47 - 54.
prevention is better than a cure. At Harrison Castings, we [6] Senthiil, P. V., M. Chinnapandian and Aakash
have a dedicated, onsite laboratory that is committed to Sirusshti, Optimization of Process Parameters In Cold
ensuring that all of our castings have the finest metallurgical Chamber Die Casting Process Using Taguchi Method,
properties. In this way, we reduce the chances of defects International Journal of Innovative Science,
even occurring in the first place. Engineering & Technology, Vol.1 Issue 6, August
2014.
We to continuously monitor our mechanical processes, our [7] Md Ainul Haque1, Prof Babuli Kumar Jena2,, Prof
sand compositions, and our alloys. As a result, we have been Dilip Kumar Mohanta3, Optimization of process
able to abandon any inefficient processes that have parameters in cold chamber Pressure die casting using
historically resulted in lower quality castings, whilst DOE, International Research Journal of Engineering
perfecting any processes that lead to higher yields and and Technology (IRJET) e - ISSN: 2395 –0056,
superior metallurgical properties [4]. Volume: 04 Issue: 04 | Apr - 2017.
[8] Utkarsh S. Khade1, Vishwajit Nimbalkar2,
2. Conclusions Application of 3D Cad Modeling and Casting
Simulation to Eliminate Casting Defects, IJRAT,
A detailed study of process parameters in high pressure die ISSN; 2321 - 9637, Special Conference NCMMM -
casting are explained with advantages and disadvantages of 2016, 19 March 2016.
many parameters along with HPDC defects such as [9] Dr. B. Ravi, Computer - aided Casting Design and
shrinkage and porosity with their effects. Simulation, STTP, V. N. I. T. Nagpur, July 21, 2009.
[10] Lus, H. M., 2011. Effect of casting parameters on the
The following observations were made, microstructure and mechanical properties of squeeze
1) Casting defects are very serious for the manufacturing cast A380 aluminum die cast alloy‖, Yildiz Technical
industry making HPDC products. University, Department of Metallurgical and Materials
2) For better quality all kinds of defects should be Engineering, Istanbul, 34210 Turkey November 2011.
minimized or free of defects. [11] URL: http: //www.chemtrend.
3) In this paper review of different research papers have com/material/alloys_metals/aluminum, accessed on
been presented and discussed. 1/9/2014.
4) The study must be validated through experimental
methods to accept the results obtained through
analytical or simulation approach.
5) At higher temperatures rough casting surfaces are
obtained, decreases the strength of casting, due to
trapped gases causing casting defects such as blow
holes.

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Volume 11 Issue 6, June 2022
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Licensed Under Creative Commons Attribution CC BY
Paper ID: SR22609200329 DOI: 10.21275/SR22609200329 694