Casting Integrity of High Pressure Die Castings
Lead Research Organisation:
Brunel University London
Department Name: Inst of Materials & Manufacturing: BCAST
Abstract
The integrity of high pressure die castings has been an area of great interest within the automotive casting industry with many novel casting alloys and processing techniques being developed to mask the deficiencies of current foundry practise. Although porosity is always observed in high pressure die castings, a great number of variables influence the integrity of the casting. Therefore manufacturing castings to a specified level of integrity is an immensely challenging process.
This project aims to understand the correlation between the integrity of the casting structure and the performance of the casting material subject to tensile and fatigue loading. The project starts with current solidification principles and applies this knowledge to analyse current foundry practise at the microstructural level, establishing which processes are optimal and ways to further enhance their potency. The casting of principle Jaguar Land Rover alloys will be made by conventional and alternative high pressure die casting processes, with full assessment of their solidification characteristics being conducted through the range of process variables.
The main objective of the proposed research is to establish the relationship between casting integrity and materials performance (tensile properties and fatigue properties) for high pressure die castings of directly made and machined samples from trial castings.
The castings of the AL9SiMg alloy with varying levels of porosity will be made via conventional and vacuum assisted high pressure die casting processes, followed by the assessment of microstructural characterisation and the examination and simulation of porosity levels utilising CT and X-ray metrology systems in conjunction with the Procast software. The materials performance including tensile properties and fatigue performance will be examined for ASTM standard samples from trial castings in association with fractographic assessment. As a result of this, a quantitative relationship between casting integrity and material performance will be established, with the intention of reducing CO2 emissions within the development of aluminium car body structures and chassis components.
The integrity of high pressure die castings is believed to be the key factor for quality control of thin wall castings. The optimised control of casting procedures will contribute to the improvement of mechanical properties and consistency of castings, due to the elimination of randomly distributed porosity, resulting in reduced safety factors relating to the compensation of casting uncertainties. This will result in the reduction of component cost and/or weight. This research will also aid JLR in the reduction of green gas emissions
This project aims to understand the correlation between the integrity of the casting structure and the performance of the casting material subject to tensile and fatigue loading. The project starts with current solidification principles and applies this knowledge to analyse current foundry practise at the microstructural level, establishing which processes are optimal and ways to further enhance their potency. The casting of principle Jaguar Land Rover alloys will be made by conventional and alternative high pressure die casting processes, with full assessment of their solidification characteristics being conducted through the range of process variables.
The main objective of the proposed research is to establish the relationship between casting integrity and materials performance (tensile properties and fatigue properties) for high pressure die castings of directly made and machined samples from trial castings.
The castings of the AL9SiMg alloy with varying levels of porosity will be made via conventional and vacuum assisted high pressure die casting processes, followed by the assessment of microstructural characterisation and the examination and simulation of porosity levels utilising CT and X-ray metrology systems in conjunction with the Procast software. The materials performance including tensile properties and fatigue performance will be examined for ASTM standard samples from trial castings in association with fractographic assessment. As a result of this, a quantitative relationship between casting integrity and material performance will be established, with the intention of reducing CO2 emissions within the development of aluminium car body structures and chassis components.
The integrity of high pressure die castings is believed to be the key factor for quality control of thin wall castings. The optimised control of casting procedures will contribute to the improvement of mechanical properties and consistency of castings, due to the elimination of randomly distributed porosity, resulting in reduced safety factors relating to the compensation of casting uncertainties. This will result in the reduction of component cost and/or weight. This research will also aid JLR in the reduction of green gas emissions
People |
ORCID iD |
| Mizi Fan (Primary Supervisor) | |
| Ewan Lordan (Student) |
Studentship Projects
| Project Reference | Relationship | Related To | Start | End | Student Name |
|---|---|---|---|---|---|
| EP/R511869/1 | 01/10/2017 | 31/12/2022 | |||
| 2043200 | Studentship | EP/R511869/1 | 01/10/2017 | 21/04/2021 | Ewan Lordan |