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<p>Gas entrapment and turbulent flow induced by high-speed metal injection disrupt and hinder the die-casting process of aluminum alloys. This paper investigates the importance and influence of injection speed on large and complex aluminum alloy die castings. The study found injection speed of 5 m/s markedly enhances the mechanical properties of the castings compared with both lower (4 m/s) and higher (6 m/s) injection speeds. This is most likely attributable to the rapid conversion of kinetic energy into thermal energy, which increases temperature and improves mobility at 5 m/s compared with 4 m/s. Whereas too high injection speed of 6 m/s may cause turbulence and spattering with the entrained gas in metal melt lowers mechanical properties. The strength and stiffness of cast parts do not change significantly with injection speed between 4, 5, and 6 m/s. Experiments show that pores, diffuse Si particles, and layered Si phases are presented around the fracture and tear ridges, which are likely to lead to stress concentration and resulting fracture. Subsequently, pore generating mechanisms and enhancement mechanisms of the anti-fracture properties via high injection speed modulation are analyzed. At injection speed of 5 m/s, the grain size is finer and uniformly distributed, with fewer pore defects, lower stress concentration, and higher strength. Melt flow dynamics simulations show that metal fluids flow at different rates in complex structures. Fracture separation of the metal fluid can be avoided when the slower metal fluid returns almost simultaneously with the faster metal fluid. This offers valuable insights for optimizing high-pressure die-casting processes in industrial applications.</p>

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Influence of High Injection Speed on Porosity and Mechanical Properties of High-Pressure Die-Casting Al–Si–Mg–Mn Alloy

  • 期刊论文

  • 发表日期：

    2025年7月16日

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  • Jian Yang,
  • Bo Liu,
  • Dongwei Shu,
  • Huizhao Li,
  • Qin Yang,
  • Tiegang Hu,
  • Zhibai Wang,
  • Yunbo Zeng,
  • Jun Huang,
  • Xiaoliang Tang

摘要

Gas entrapment and turbulent flow induced by high-speed metal injection disrupt and hinder the die-casting process of aluminum alloys. This paper investigates the importance and influence of injection speed on large and complex aluminum alloy die castings. The study found injection speed of 5 m/s markedly enhances the mechanical properties of the castings compared with both lower (4 m/s) and higher (6 m/s) injection speeds. This is most likely attributable to the rapid conversion of kinetic energy into thermal energy, which increases temperature and improves mobility at 5 m/s compared with 4 m/s. Whereas too high injection speed of 6 m/s may cause turbulence and spattering with the entrained gas in metal melt lowers mechanical properties. The strength and stiffness of cast parts do not change significantly with injection speed between 4, 5, and 6 m/s. Experiments show that pores, diffuse Si particles, and layered Si phases are presented around the fracture and tear ridges, which are likely to lead to stress concentration and resulting fracture. Subsequently, pore generating mechanisms and enhancement mechanisms of the anti-fracture properties via high injection speed modulation are analyzed. At injection speed of 5 m/s, the grain size is finer and uniformly distributed, with fewer pore defects, lower stress concentration, and higher strength. Melt flow dynamics simulations show that metal fluids flow at different rates in complex structures. Fracture separation of the metal fluid can be avoided when the slower metal fluid returns almost simultaneously with the faster metal fluid. This offers valuable insights for optimizing high-pressure die-casting processes in industrial applications.