Process parameter influence on selected quality features in high-pressure die casting

The comprehension of coherences between process parameters and cast part quality in high-pressure die casting is an important step towards a robust process. The presented study focusses on the influence of process parameters that are believed to be of great importance on the cast part quality such as the Ming velocity, the intensification pressure or the die temperature. Quality measures like the cast part porosity and mechanical properties are to be linked with process conditions in order to separate the influence of the die layout and the effects resulting from process variations from each other. In the presented paper, the conduction routine and results of a detailed study which has been performed in order to understand these interdependencies for a twin cavity die are shown. This die is used to produce plate shaped cast parts, featuring a highly modular setup consisting of seven different inserts. The variable setup is the foundation for further investigations e.g. the influence of conformal cooling and additive manufacturing for die inserts such as Selective Laser Melting. In addition to the modular setup, the die is equipped with more than ten temperature sensors per cavity, which are used to monitor the influence of the process parameters on the die itself. The collected data and the interchangeability of the die components will be used for further improvement of a numerical optimization routine that is developed in this context.