Injection Parameters Setting in High-Pressure Die Casting

This introductory paper is the research content of the paper "Injection Parameters Setting in High-Pressure Die Casting" published by STM Journals.

Figure 1. Cold chamber horizontal high pressure die casting machine.
Figure 1. Cold chamber horizontal high pressure die casting machine.

1. Overview:

  • Title: Injection Parameters Setting in High-Pressure Die Casting
  • Author: Rahul B., Bhaskar M. Reddy, Tamilselvam Nallusamy, W. Brightlin Abisha, Suresh P.
  • Publication Year: 2023
  • Published Journal/Society: Journal of Polymer & Composites (Volume 11, Special Issue 13)
  • Keywords: Casting defects, Cavity pressure, Fill time, Gate area, Injection velocity

2. Abstract

The advancement of science and processing technology is highly essential. Aluminium die-cast components are widely used. Proper process parameters are required. This paper studies optimum injection parameters. The common defects encountered in high pressure die casting process (HPDC) are cold shut, flow line, blowholes, pinholes, shrinkage, gas entrapment porosity, etc. This research analyses the effect of slow speed, fast speed, and intensification features. Optimum value for the injection parameters such 1st phase length, 1st phase velocity, 2nd phase length, 2nd phase velocity, 3rd phase cavity pressure & holding time are estimated.

3. Research Background:

Background of the research topic:

Metals and alloys, especially aluminum, are widely used in engineering applications, including automobiles, composites, and aerospace, due to properties like high strength-to-weight ratio and corrosion resistance [1-6]. Die casting processes are categorized into Gravity Die Casting (GDC), Low Pressure Die Casting (LPDC), and High Pressure Die Casting (HPDC) [7–9].

Status of previous research:

  • Gravity Die Casting (GDC): Uses gravitational and atmospheric pressure. Recommended for parts with wall thicknesses greater than 6 mm, casting weights from 3 to 25 kgs, but has a lower production rate than HPDC [10–14].
  • Low Pressure Die Casting (LPDC): Uses pressurized gas (0.1-0.3 bar) to fill the mold cavity [9, 17]. Used for automobile parts like wheels and cylinder heads [18].
  • High-Pressure Die Casting (HPDC): Involves a piston driving molten metal at high pressure and velocity [19–23]. Die sets are made of H13 steel, hardened to 44-46 HRC, and often nitrided [24, 25, 26].

Need for research:

Variations in injection parameters (slow speed, fast speed, intensification pressure, etc.) can lead to casting defects. Proper settings are essential for high-quality, defect-free castings.

4. Research purpose and research question:

Research purpose:

To study and optimize injection parameters in HPDC to reduce casting defects.

Core research:

To analyze the effects of the three phases of injection (slow speed, high speed, and intensification) and determine optimal values for:

  • 1st phase length and velocity
  • 2nd phase length and velocity
  • 3rd phase cavity pressure and holding time

5. Research methodology

The research analyzes the three-phase injection system (Figure 2) in HPDC, focusing on:

  • Filling Ratio: The ratio of poured liquid metal volume to the total injection sleeve volume. A 60-70% filling ratio is recommended to minimize gas entrapment porosity [33–36].
  • 1st Phase (Prefilling Phase): Plunger moves molten metal to near the in-gate at low velocity (0.1 m/sec to 0.6 m/sec) [37]. The 1st phase length and velocity are calculated using formulas provided by the North American Die Casting Society (NADCA).
  • 2nd Phase (Die Cavity Filling Phase): Liquid metal is injected at high speed (0.4 m/sec–6 m/sec). Mold filling time is very short (5 to 100 milliseconds). 2nd phase length and velocity are calculated based on die design data, gate area, and gate velocity.
  • 3rd Phase (Intensification Phase): Extra metal is pushed in during solidification to compensate for shrinkage. Intensification pressure (cavity pressure) is calculated, and different pressures are recommended for different types of castings [38-42].

The study uses these principles to analyze an engine housing component, with specific data provided for shot weight, casting weight, gate area, plunger diameter, and active sleeve length.

6. Key research results:

Key research results and presented data analysis:

The study calculated the injection parameters for the engine housing component step-by-step:

  1. Shot Weight Volume, Casting Weight Volume, and Shot Sleeve Volume: Calculated based on provided data.
  2. Fill Ratio: Calculated as 58.53%, close to the optimal 60-70%.
  3. 2nd Phase Length: Calculated as 12.03 cm.
  4. 1st Phase Length: Calculated as 16.97 cm.
  5. 1st Phase Velocity: Calculated as 0.077 m/sec, within the recommended range.
  6. 2nd Phase Velocity: Calculated as 1.55 m/sec.
  7. Intensification (Cavity) Pressure: Calculated as 933 kg/cm², within the recommended range for pressure-tight castings.

These optimized parameters were then implemented in a production setting.

Table 1 summarizes the parameters before and after the research, showing improvements in air entrapment, cavity filling time, pressure tightness, and a reduction in rejection rates from 8% to 1.2%.

Figure 2. Three-phase injection system.
Figure 2. Three-phase injection system.
Table 1. Research analysis and results
Table 1. Research analysis and results

List of figure names:

  • Figure 1. Cold chamber horizontal high pressure die casting machine.
  • Figure 2. Three-phase injection system.

7. Conclusion:

Summary of key findings:

By optimizing the injection parameters (1st phase length & velocity, 2nd phase length & velocity, and 3rd phase cavity pressure & holding time), the rejection rate of castings was significantly reduced from 8% to 1.2%.
The research demonstrates that careful control and calculation of injection parameters in HPDC are crucial for producing high-quality, defect-free castings. The practical implication is a significant reduction in scrap and improved production efficiency, leading to increased profit and customer satisfaction.

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9. Copyright:

  • This material is a paper by "Rahul B., Bhaskar M. Reddy, Tamilselvam Nallusamy, W. Brightlin Abisha, Suresh P.": Based on "Injection Parameters Setting in High-Pressure Die Casting".
  • Source of paper: DOI (Journal): 10.37591/JoPC

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Tags: Al-Si alloy; ,CFD; ,Die casting; ,Efficiency; ,High pressure die casting; ,High pressure die casting (HPDC); ,Microstructure; ,Salt Core; ,Taguchi method