THE RELATIONSHIP BETWEEN DENDRITE ARM SPACING AND COOLING RATE OF Al-Si CASTING ALLOYS IN HIGH PRESSURE DIE CASTING

The effects of cooling rate on the solidification behavior of Al-8.5%Si-3%Cu and Al-11%Si-3%Cu alloys were studied during high pressure die casting (HPDC). The HPDC experiment was conducted by using the dies with three steps for three different cooling rates. Because of both high temperature and pressures involved, it was difficult to obtain the temperature profile directly from HPDC specimen. Therefore, in this study, cylindrical bar castings with different diameter were poured to acquire the cooling curves at the solidification range of 15 degrees C/s up to 100 degrees C/s and then the microstructures were compared to estimate the cooling rate in HPDC. The solidification characteristics including liquidus/solidus temperature and dendrite arm spacing of each alloy and each cooling rate was analyzed and the results showed strong proportional relationship between dendrite arm spacing (DAS) and cooling rate in HPDC. The results were also compared with the actual die casting specimens and MAGMA simulation.