High Pressure Die Casting of Zamak alloys

This introductory paper is the research content of the paper "High Pressure Die Casting of Zamak alloys" published by [FEUP FACULDADE DE ENGENHARIA UNIVERSIDADE DO PORTO].

1. Overview:

• Title: High Pressure Die Casting of Zamak alloys
• Author: Steven Richard Pires de Oliveira
• Publication Year: July 2018
• Publishing Journal/Academic Society: Dissertação de Mestrado (Master's Thesis), Mestrado Integrado em Engenharia Mecânica, FEUP FACULDADE DE ENGENHARIA UNIVERSIDADE DO PORTO
• Keywords: Fundição injetada; ligas Zamak; sistema de gitagem; NADCA; ProCAST; Vácuo; Exco Engineering.(Injection casting, Zamak alloys, gating system, NADCA, ProCAST, Vacuum, Exco Engineering.)

2. Abstracts / Introduction

The high pressure die casting (HPDC) process has seen significant advancements, especially within the automotive sector. While aluminum alloys are commonly used, zinc alloys, particularly Zamak, are gaining traction due to their excellent surface quality and high production rates. This thesis explores the HPDC of Zamak alloys, focusing on optimizing gating systems to reduce porosity defects caused by turbulent metal flow. It also investigates the application of vacuum technology to further improve part quality. The generation of high quantities of air during the filling process is a critical problem that often leads to air porosity related defects. The vacuum technology is being used to overcome defects related to air entrapments.

3. Research Background:

Background of the Research Topic:

The HPDC is a metal casting process, were liquid metal is injected into a reusable metal mould at high velocities along with high pressures.
In this process there are two types of die casting machines, the cold chamber machine and hot chamber machine. The hot chamber machine is reserved for lower melting point alloys such as zinc, tin, lead and some magnesium alloys.

Status of Existing Research:

Existing research highlights the challenges of porosity in HPDC, particularly with Zamak alloys. Optimization of gating systems and process parameters is a known approach, but often relies on designer experience. Vacuum-assisted HPDC is widely used for aluminum and magnesium, but less common for zinc alloys. Literature on detailed vacuum system design for Zamak is limited.

Necessity of the Research:

Zamak alloys, are a specific family with zinc as its main element, following aluminium, copper and magnesium. High density and high creep rate at low temperatures are the two main problems of using these alloys. This limits their usage on the “light weight” market. For these reasons, new ways to overcome these disadvantages are needed, so that Zamak alloys can have a wider market share. The gating system design is a major task because it not only affects the manufacturing of the die but also the quality and cost of the produced components.

4. Research Purpose and Research Questions:

Research Purpose:

This thesis aims to develop a more scientific approach to gating system design for HPDC of Zamak alloys, utilizing a spreadsheet-based calculation method. It also aims to explore and explain the vacuum technology in detail and its viability in high pressure die casting process of Zamak alloys will be investigated.

Key Research:

• Develop a best practice manual for designing a gating systems.
• Apply a desighing procedure in a real case.
• Investigate effectiveness of optimized gating systems via simulation (ProCAST).
• Investigate the application of vacuum technology, including a design methodology for vacuum systems.

5. Research Methodology

Research Design:

• Literature review of HPDC, Zamak alloys, gating system design, and vacuum technology.
• Development of a gating system design methodology.
• Case study application: analysis of an existing component with high rejection rates (over 35 %).
• Iterative design and simulation of gating systems.
• Exploration of vacuum system design principles and application.

Data Collection Method:

• CAD models of components and gating systems.
• Material properties and process parameters from industrial partners (STA).
• Simulation results from ProCAST.

Analysis Method:

• Gating system convergence analysis using CAD.
• Flow simulation using ProCAST to predict filling patterns, velocities, and air entrapment.
• Application of NADCA gating design guidelines.
• Vacuum system design calculations using Exco Engineering App.

Research Subjects and Scope:

• Focus on Zamak alloys in hot chamber HPDC.
• Analysis of a specific industrial component.
• Gating system design and optimization.
• Vacuum system design principles and application to the case study.

6. Main Research Results:

Key Research Results:

• A structured gating system design procedure based on NADCA guidelines was presented.
• A case study demonstrated the impact of optimized gating on reducing air entrapment.
• Simulation results (ProCAST) correlated with real-world defect observations (blistering).
• A method of designing vacuum system is proposed.

Analysis of presented data:

• Iteration 1 (Existing Design): Non-convergent gating system, non-uniform metal velocity, high air entrapment predicted by simulation, and validated by RX analysis.
• Iteration 2 (Optimized Design): NADCA-based design, improved metal flow, reduced air entrapment in simulation.
• Iteration 3 (Modified Existing Design): Improved overflow location and runner design, further reduction in air entrapment, validated by a decreased rejection rate in production (from 35% to 5%).

Figure Name List:

Figure 1- Comparison of properties of different foundry processes [1].
Figure 2- Manufacturing conveniences of different foundry processes as function of production rate and casting weight [2].
Figure 3- Representation of casting processes respecting velocity and pressure [3].
Figure 4- Sturges die casting machine patent [5].
Figure 5- Early die casting machine that required two people to operate [5].
Figure 6- Pneumatic die casting machine [5].
Figure 7- Left: Shock tower with an assembly of various sheet steel parts; Right: Same part with just a single part produced by aluminium die casting [10].
Figure 8- High pressure die casting process [2].
Figure 9- Left: Schematics of a conventional HPDC cold chamber machine [14]; Right: Typical layout of a component produced by a cold chamber machine [15].
Figure 10- Classification of defects and their origins [16].
Figure 11- Left: Schematics of a conventional HPDC hot chamber machine [14]; Right: Components produced by a hot chamber machine [22].
Figure 12- Passage connecting the nozzle to the die cavity of a hot chamber machine [23].
Figure 13- Projected area of casting which includes, die cavity, overflows, gating system, vacuum valves and runners [22].
Figure 14- High pressure die casting process phases; representing piston speed and pressure as function of piston position [1].
Figure 15- Zamak components ( Courtesy of Dynacast) [30].
Figure 16- Left: Cast components being subjected to a grinding process; Right: abrasive chips [32].
Figure 17- Left: Zamak 5; Right: Zamak 5 + 0.10 wt.% hf. Both allots at 200x magnification [35].
Figure 18- Components of a unit die assembly [23].
Figure 19- Flow chart of the simulation process based on ProCASTTM [43].
Figure 20- Die casting mold manufactured with TOOLOX 44 to inject Zamak [40].
Figure 21- Salt core and die casting with cavity [47].
Figure 22- Left- “Triplet” salt core inserted in the die cavity; Right- Injected part of a zinc alloy [45].
Figure 23- Water soluble salt core with bauxite powders and glass fibres for a zinc alloy casting [50].
Figure 24- Thermal images of the die after spraying (left) with an average surface temperature of 180 ºC, and before spraying (right) [52].
Figure 25- Protrusions related to lamination. Left: magnified 25 x; Right: magnified 10 x [52].
Figure 26- Deformation present on a manufactured part [52].
Figure 27- Surface roughness duo to soldering [52].
Figure 28- Examples of components using the gas injection technology using a cold chamber [10].
Figure 29- Possible applications for gas injection technology in the high pressure die casting technology. Left: intake manifolds; Right: Hollow structures in clutch pedals [57].
Figure 30- Control-related of the die casting machine and thee gas unit [10].
Figure 31- Home position and filling phase [10].
Figure 32- Gas injection and opening of the cavity overflow [10].
Figure 33- Shot curve with different process parameters [10].
Figure 34- Simulation of die fill indicating cold metal near the gas injector for Gating [57].
Figure 35- Pressure die casting tool for gas injection and a 200 ton cold chamber casting machine. 1- Overflow Cavity; 2- Locking Pin; 3-Injector; 4- runner; 5-Runner 2 [57].
Figure 36- Zinc high pressure die casting with a cavity completely produced by gas injection [58].
Figure 37- Left: Non plana filling; Right: planar filing [60].
Figure 38- Hot chamber rheo-diecasting machine. The circle indicates de magnetic field around the nozzle [62].
Figure 39- Microstructure of a magnesium alloy, AZ91D. Left: conventional high pressure die casting, Right: hot chamber rheo-die casting [62].
Figure 40- Effect of test temperature (-35, 23,85 ºC) and wall thickness on the tensile strength of Zamak 5 during different natural ageing durations [38].
Figure 41- Hardness evolution of a Zamak 5 alloy during 1 year natural ageing [38].
Figure 42- Artificial ageing of Zamak 5 alloy for 25 hours for 3 different temperatures [38].
Figure 43- Elements of a gating system [75].
Figure 44- Flow chart for die layout design [39].
Figure 45- Atomized flow [24].
Figure 46- Curve sided fan runner-gate [24].
Figure 47- Straight sided fan runner-gate [24].
Figure 48- Left: Top view of a curved sided fan divided into 9 sections; Right: Cross sectional view of a fan gate-runner and main runner [24].
Figure 49- Tapered tangential gate-runner that illustrates different flow angles [24].
Figure 50- Typical overflow sizes [24].
Figure 51- Overflow.
Figure 52- Location of vents on the die [24].
Figure 53- Left: Blistering; Right: Pin holes.
Figure 54- CAD model for a gating system which was responsible of a rejection rate of over 35 %.
Figure 55- Cross section of the die cavity for iteration 1.
Figure 56- Analysis of the cross-sectional area of the gating system.
Figure 57- Overview of the work flow for a simulation tool.
Figure 58- Velocity evolution at t=16.8ms and 35.2% filled.
Figure 59- Velocity evolution at each ingate.
Figure 60- Velocity profile and representation of the metal front collision and creation of air pockets.
Figure 61- Air entrapment prediction during the filling process.
Figure 62- Rx analysis after painting process.
Figure 63- Optimized gating system for iteration 2.
Figure 64- Simulation results of the entire component and gating system.
Figure 65- Molten metal velocity in function of die cavity filling time at 3 points.
Figure 66- Molten velocity profile representing 3 different points.
Figure 67- Air entrapment prediction using ProCASTTM.
Figure 68- CAD model of iteration 3.
Figure 69- Molten metal velocity profile function to cavity filling time.
Figure 70- Metal flow in the components die cavity, representing the occurrence of air pockets during the injection process.
Figure 71- Prevision of air entrapments using simulation.
Figure 72- Two examples of Zinc alloy components produced by vacuum high pressure die casting (Courtesy of Fondarex) [79].
Figure 73- Comparison of conventional HPDC, vacuum-assisted HPDC and super-vacuum die casting [1].
Figure 74- Case study presenting the internal die cavity pressure and air mass for a HPDC vacuum process including and excluding a leakage area [93].
Figure 75- Die cavity pressure with respect to different slow shot speed [97].
Figure 76- Average area of gas porosity with respect to different slow shot speeds [97].
Figure 77- Influence of different slow shot speed on mechanical properties: UTS, YS, elongation [97].
Figure 78- Mechanical properties variation with respect to different gate velocity [84].
Figure 79- Incorrect vacuum gating system design, with blocked zones A and B [92].
Figure 80- A- Incorrect vacuum gating design; B-Optimized design [92].
Figure 81- Vacuum die casting system [98].
Figure 82- Left- Schematic of a corrugated chill block [4]; Right- ProVac chill vent [99].
Figure 83- Left: Chill block with a triangular cross-sectional shape; Right: Chill block with a trapezoidal cross-sectional shape [101].
Figure 84- Mechanical shut-off vacuum valve with the Typhon vacuum runners [99].
Figure 85- Vacuum runner for a mechanical vacuum valve [100].
Figure 86- Left: Electro-pneumatic valve [102]; Right: Hydraulic vacuum shut-off valve [4].
Figure 87- Performance comparing of a vacuum valve and chill vent [99].
Figure 88- Pressure measurement of a vacuum shut-off valve. Left: Aspiration is opened; Right: Aspiration is closed [99].
Figure 89- Differences between a mechanical valve and a chill vent [99].
Figure 90- Left: Representation of one half, consisting of wedge-shaped inserts; Right: Engagement of two halves [100].
Figure 91- Left: Pressure changes in the vacuum line for a mechanical and a CASTvac valve; Right: Pressure changes in a 3L vacuum vessel for a chill vent and a CASTvac [100].
Figure 92- CASTvac installed in a die [100].
Figure 93- Different venting efficiencies for a CASTvac and a chill block with natural and vacuum venting [93].
Figure 94- Different venting efficiencies with for different venting methods and evacuation devices [93].
Figure 95- Gibbs vertical vacuum die casting process [14].
Figure 96- Discharge coefficient of vacuum valve and chill block [98].
Figure 97- Venting mass flow rates [98].
Figure 98- Vacuum tank sizing using the Exco Engineering application.
Figure 99- Vent valve sizing using Exco engineering application.
Figure 100- Vacuum pull time estimation using a mechanical vacuum valve.
Figure 101- Vacuum pull time estimation using a chill block.
Figure 102- Evolution of the die cavity pressure with respect to the plunger position [105].
Figure 103- Examples of a vacuum runner system layout with a mechanical vacuum valve [106].
Figure 104- Cross-sectional area variation of the vacuum runner system [106].
Figure A 1- Figure presenting different dimensions of the fan gate-runner calculated in Table A 6.
Figure A 2- Various dimensions of an overflow.
Figure A 3- Dimensions of a tangential gate-runner.

7. Conclusion:

Summary of Key Findings:

• Optimized gating systems, designed using established guidelines (NADCA) and simulation, significantly reduce air entrapment in HPDC of Zamak alloys.
• Real-world production results validated simulation predictions, demonstrating the value of CAE tools.
• The Exco Engineering App offers an easy to use tool for the designing process of a venting system.

Academic Significance of the Study:

• Provides a structured methodology for gating system design in Zamak HPDC, moving beyond reliance on experience alone.
• Demonstrates the effectiveness of simulation in predicting and mitigating defects.
• Contributes to the understanding of vacuum technology application in Zamak HPDC.

Practical Implications:

• Improved gating design can lead to reduced scrap rates and improved part quality.
• Simulation tools can be used to optimize designs before tooling, saving time and cost.
• Vacuum technology offers a potential solution for applications requiring high-quality Zamak components.

Limitations of the Study and Areas for Future Research:

• The vacuum system design application had limitations (bugs) preventing complete validation.
• The study focused on a single component; further research could explore different geometries and alloys.
• Future research should investigate:
  • Influence of heat treatments (T4, T5, T6) on Zamak alloys in HPDC.
  • Practical implementation of the optimized gating system (Iteration 2).
  • Real-world application of the vacuum system design methodology.

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9. Copyright:

• This material is "Steven Richard Pires de Oliveira"'s paper: Based on "High Pressure Die Casting of Zamak alloys".
• Paper Source: [There is no DOI URL, ResearchGate URL : https://repositorio-aberto.up.pt/bitstream/10216/113790/2/276778.pdf]

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