Study On Porosity And Process Optimization Of Hypereutectic Al-Si Alloy Die Casting

In this contribution, the effects of five important process parameters, metal temperature, casting pressure, fast shot speed, fast shot set point on the properties of die casting R14 aluminum alloy air-conditioning compressor cylinder were investigated by the method of measuring the density of as-cast and heat treated casting,analyzing microstructure and testing the tensile properties.Numerical simulation is also used to describe the flow and temperature distribution at the different metal temperature, fast shot speed and fast shot set point in the platform of AnyCastingTM using Finite difference method.The result showed that higher metal temperature and fast shot speed increase the amount of the porosity; an increase in fast shot set point decrease the amount of the porosity; an increase in pressure increase the porosity first and then decrease. An increase in metal temperature decrease the UTS and elongation; an increase in fast shot speed and fast shot set point increase the UTS and elongation and the decrease; an increase in casting pressure increase the UTS and elongation. The optimum combination of modifying agent, melt temperature, casting pressure, fast shot speed and fast shot set point for generating the lowest porosity were HGPB-1 modifying agent, 700℃-720℃, 104Mpa, 1.5m/s, 320mm, respectively.