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<p>In this study, a Gas-Induced Semi-Solid (GISS) high-pressure die casting (HPDC) process combined with squeeze pin assistance was developed to improve the casting quality of high-strength aluminum alloys (7075, A201, and 383). The study investigated the influence of solid fraction on the semi-solid slurry characteristics, as well as the effect of the squeeze pin assistance on the fill fraction, holding time, macrostructure, microstructure, and mechanical properties of the cast alloys. The resulting Semi-Solid Metal Die Casting (SSMDC) samples were compared with those produced by conventional die casting. By optimizing squeeze pin timing, fill fraction, and solid fraction, hot tearing and solidification-related defects were significantly reduced. The incorporation of the GISS technique promotes the formation of uniform, globular grain structures in the semi-solid slurry, thereby enhancing the mechanical properties of all three aluminum alloys. For SSMDC 7075, an optimized solid fraction of 21.2% resulted in defect-free microstructures and tensile properties of 229&#xa0;MPa with an elongation of 10.2%. Similarly, SSMDC A201 processed at a solid fraction of 15.7% exhibited improved structural integrity, achieving a tensile strength of 169&#xa0;MPa and elongation of up to 22.6% while SSMDC 383 at 6.3% solid fraction exhibited higher tensile strength (227&#xa0;MPa) compared with conventional die casting (174&#xa0;MPa). These findings demonstrate that precise control of squeeze pin timing and fill fraction under semi-solid flow conditions, together with an optimized solid fraction is the key innovation enabling enhanced mechanical performance and effective defect control in GISS-based SSMDC.</p>

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Gas-Induced Semi-Solid HPDC with Squeeze Pin Assistance for High-Strength Aluminum Alloys (7075, A201, and 383)

  • 期刊论文

  • 发表日期：

    2026年3月9日

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  • Si Thu Myint Maung,
  • Somjai Janudom,
  • Narissara Mahathaninwong,
  • Chadanuch Khuntrakool,
  • Seppo Karrila,
  • Jitjaroen Sawatdiwong,
  • Jessada Wannasin

摘要

In this study, a Gas-Induced Semi-Solid (GISS) high-pressure die casting (HPDC) process combined with squeeze pin assistance was developed to improve the casting quality of high-strength aluminum alloys (7075, A201, and 383). The study investigated the influence of solid fraction on the semi-solid slurry characteristics, as well as the effect of the squeeze pin assistance on the fill fraction, holding time, macrostructure, microstructure, and mechanical properties of the cast alloys. The resulting Semi-Solid Metal Die Casting (SSMDC) samples were compared with those produced by conventional die casting. By optimizing squeeze pin timing, fill fraction, and solid fraction, hot tearing and solidification-related defects were significantly reduced. The incorporation of the GISS technique promotes the formation of uniform, globular grain structures in the semi-solid slurry, thereby enhancing the mechanical properties of all three aluminum alloys. For SSMDC 7075, an optimized solid fraction of 21.2% resulted in defect-free microstructures and tensile properties of 229 MPa with an elongation of 10.2%. Similarly, SSMDC A201 processed at a solid fraction of 15.7% exhibited improved structural integrity, achieving a tensile strength of 169 MPa and elongation of up to 22.6% while SSMDC 383 at 6.3% solid fraction exhibited higher tensile strength (227 MPa) compared with conventional die casting (174 MPa). These findings demonstrate that precise control of squeeze pin timing and fill fraction under semi-solid flow conditions, together with an optimized solid fraction is the key innovation enabling enhanced mechanical performance and effective defect control in GISS-based SSMDC.