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<p>High-pressure die casting produces parts with good mechanical properties, although they face several limitations: oxide films, porosity, and shrinkage. The turbulence resulting from the fast injection of the liquid metal into the die produces parts with a typical porosity between 2 and 5%, while processing via semisolid technology with a more controlled filling front decreases this porosity to less than 1%. Despite these advantages, SSM has found a lower adoption and use in the foundry industry. This work presents the metallurgical and mechanical aspects of parts produced with HPDC, compared to rheocasting and thixoforming, using similar processing characteristics, such as injection speed and part mass. For rheocasting, the SSM slurry was prepared using inert gas bubbling through the liquid in a method analogous to the commercial GISS, and for thixoforming, heating of the chemically refined alloy billets. Rheocasting and thixoforming were proved more reliable in producing high-integrity parts than HPDC. The 356 alloy processed via GISS 5s achieved the best overall result. The microstructure consists of a mixture of rosette Alα phase surrounded by the Alα/SiD eutectic. This microstructure achieved YS of 126&#xa0;MPa, UTS of 185&#xa0;MPa, elongation of 5.1%, and 72 HV. Higher-than-expected UTS of 145 and elongation of 3% for this alloy. The T6 heat treatment improves the mechanical properties, achieving YS of 166 MPa, UTS of 205&#xa0;MPa, elongation of 3.2%, and 91&#xa0;HV. For GISS 5s, the fracture surface presented a ductile fracture appearance with dimples and tear ridges, indicating plastic deformation before failure. The same occurs for the sample in condition T6.</p>

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Die Casting, Rheocasting, or Thixoforming? Comparison of Production Strategies Using the 356 Aluminum Alloy

  • 期刊论文

  • 发表日期：

    2025年4月1日

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  • Fernando Almeida da Silva Fernandes,
  • André Victor Rodrigues Dantas,
  • João Paulo de Oliveira Paschoal,
  • Wendel Leme Beil,
  • Hipólito Domingo Carvajal Fals,
  • Eugênio José Zoqui

摘要

High-pressure die casting produces parts with good mechanical properties, although they face several limitations: oxide films, porosity, and shrinkage. The turbulence resulting from the fast injection of the liquid metal into the die produces parts with a typical porosity between 2 and 5%, while processing via semisolid technology with a more controlled filling front decreases this porosity to less than 1%. Despite these advantages, SSM has found a lower adoption and use in the foundry industry. This work presents the metallurgical and mechanical aspects of parts produced with HPDC, compared to rheocasting and thixoforming, using similar processing characteristics, such as injection speed and part mass. For rheocasting, the SSM slurry was prepared using inert gas bubbling through the liquid in a method analogous to the commercial GISS, and for thixoforming, heating of the chemically refined alloy billets. Rheocasting and thixoforming were proved more reliable in producing high-integrity parts than HPDC. The 356 alloy processed via GISS 5s achieved the best overall result. The microstructure consists of a mixture of rosette Alα phase surrounded by the Alα/SiD eutectic. This microstructure achieved YS of 126 MPa, UTS of 185 MPa, elongation of 5.1%, and 72 HV. Higher-than-expected UTS of 145 and elongation of 3% for this alloy. The T6 heat treatment improves the mechanical properties, achieving YS of 166 MPa, UTS of 205 MPa, elongation of 3.2%, and 91 HV. For GISS 5s, the fracture surface presented a ductile fracture appearance with dimples and tear ridges, indicating plastic deformation before failure. The same occurs for the sample in condition T6.