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Large-size high-pressure die castingsDie casting (HPDCHigh-Pressure Die Casting (HPDC)) are of growing interest in automotiveAutomotive applications for part consolidation. Within these large castingsCasting, local cooling rate and chemistry can vary significantly, which affects local microstructureMicrostructure and mechanical propertiesMechanical properties. Since laboratory-scale HPDCHigh-Pressure Die Casting (HPDC) systems are generally not available to study microstructural variability, we developed a laboratory-scale, instrumented procedure using a conical steel mold to determine secondary dendrite arm spacing (SDAS) and phase formation as a function of cooling rate. This procedure can be applied to study microstructural variations within HPDCHigh-Pressure Die Casting (HPDC) or castingsCasting in general. The conical steel mold produced variable cooling rates over 3 orders of magnitude in a single castingCasting made of C611 aluminum alloyAluminum alloy. X-ray radiography confirmed the position of thermocouples and metallographyMetallography was used to measure SDAS at these same positions. For a high-Fe alloy variant of C611 with Fe/Mn = 1.4, we correlated Fe-containing phases with the local cooling rate. This procedure can be used for other HPDCHigh-Pressure Die Casting (HPDC) alloys and has the potential to be automated, which would accelerate the development of mega-castingsCasting.

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Microstructure-Based Approach to Map Local Cooling Rate in High-Pressure Die Castings

  • 会议论文

  • 发表日期：

    2026年

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  • Katherine Rader,
  • Jung-Pyung Choi,
  • Aashish Rohatgi

摘要

Large-size high-pressure die castingsDie casting (HPDCHigh-Pressure Die Casting (HPDC)) are of growing interest in automotiveAutomotive applications for part consolidation. Within these large castingsCasting, local cooling rate and chemistry can vary significantly, which affects local microstructureMicrostructure and mechanical propertiesMechanical properties. Since laboratory-scale HPDCHigh-Pressure Die Casting (HPDC) systems are generally not available to study microstructural variability, we developed a laboratory-scale, instrumented procedure using a conical steel mold to determine secondary dendrite arm spacing (SDAS) and phase formation as a function of cooling rate. This procedure can be applied to study microstructural variations within HPDCHigh-Pressure Die Casting (HPDC) or castingsCasting in general. The conical steel mold produced variable cooling rates over 3 orders of magnitude in a single castingCasting made of C611 aluminum alloyAluminum alloy. X-ray radiography confirmed the position of thermocouples and metallographyMetallography was used to measure SDAS at these same positions. For a high-Fe alloy variant of C611 with Fe/Mn = 1.4, we correlated Fe-containing phases with the local cooling rate. This procedure can be used for other HPDCHigh-Pressure Die Casting (HPDC) alloys and has the potential to be automated, which would accelerate the development of mega-castingsCasting.