MC-HPDCMelt conditioned high pressure die casting

MC-HPDCMelt conditioned high pressure die casting

BCAST (Brunel Centre for Advanced Solidification Technology)

Brunel University

UK

MC-HPDC processMC-HPDC process

MC-HPDC = MCAST+ HPDC

MCAST

T/C

Inlet

T/C

HPDC Machine

HPDC vs. MC-HPDCHPDC vs. MC-HPDC

  

 

AD91D

HPDC

MC-HPDC

fs=0.31d=53

fs=0.32d=54

fs=0.32d=53

fs=0.30d=53

fs=0.32d=54

fs=0.32d=53

Uniform microstructure throughout the component (LM24)

Uniform microstructure throughout the component (LM24)

Property comparison Property comparison

125

150

175

200

225

250

275

0 2 4 6 8

Elongation (%)

UT

S (

MP

a)

HPDC

Thixo-cast

Thixo-moulded

MC-HPDC

AZ91D

Property comparison with other processes(357 alloy)

Property comparison with other processes(357 alloy)

  

 

240

250

260

270

280

290

300

310

0 2 4 6 8 10 12

Elongation (%)

UT

S (

MP

a)

New rheocasting (T5)Thixocasting (T5)MC-HPDC (F)MC-HPDC (T5)

Substantially increased fatigue lifeSubstantially increased fatigue life

AZ91D

10-3

10-2

10-1

100 101 102 103 104 105 106 107

Fatigue life (reversals)

Str

ain

am

pli

tud

e

HPDC 700oCMC+HPDC 630oC

MC+HPDC 587oC

LM24

10-3

10-2

10-1

100 101 102 103 104 105 106 107

Fatigue life (reversals)

Str

ain

am

pli

tud

e

HPDC 700oCMC+HPDC 630oC

MC+HPDC 587oC

LM24

Direct recycling of Mg scrapDirect recycling of Mg scrap

0

50

100

150

200

250

300

100%Scrap 50%Scrap Primary

Material Conditions

Yie

ld,

UT

S (

MP

a)

0

1

2

3

4

5

6

7

8

Elo

nga

tion

(%)

Yield UTS Elongation

AZ91D

Increased Fe tolerantIncreased Fe tolerant

2.0

2.5

3.0

3.5

4.0

0.0 0.5 1.0 1.5 2.0 2.5

Fe content (wt.%)

Elo

ngatio

n

(%)

RDC

HPDC

0.0

2.0

4.0

6.0

8.0

10.0

12.0

0.3 0.5 0.7 0.9 1.1 1.3Fe content (wt.%Fe)

Elo

ngation (

%)

RDC

HPDC

LM24(Al-9.3Si-3.2Cu-1.58Zn-0.3Mn)

LM25(Al-10.3Si-0.3Cu-0.16Mn)

Fe tolerance = 0.7wt% Fe tolerance = 0.37wt%

Advantages of MC-HPDC over HPDCAdvantages of MC-HPDC over HPDC

Increased fluidity and enhanced die filling due to dispersed oxide films and lumps of inclusions

Reduced melt temperature sensitivity

Reduced porosity (<0.5vol%) and well dispersed porosity

Reduced hot tearing

Fine and uniform microstructure throughout the entire component

Increased strength and ductility

Increased fatigue life

Direct recycling of scrap metal without degradation of properties

Increased tolerance to impurity elements

Increased range of die-castable alloys