The effect of die casting machine parameters on porosity of aluminium die castings

The primary objective of this research is to investigate the effect of machine related parameters on porosity formation in the aluminum die casting process. The amount and distribution of porosity in die castings was examined in relation to plunger velocity during the 1st phase, fast shot set point, plunger velocity during the 2nd phase, die cavity filling time and multiplied pressure during the 3rd phase. Standard statistical analysis was performed in order to identify the effect of each of the considered parameters and parameter interactions on porosity formation. It was found that, among the parameters considered, multiplied pressure, plunger velocity in the 2nd phase and die cavity filling time have the most significant effect on porosity formation. Using optimal die casting machine parameter levels, the optimum porosity value of aluminum alloy die-castings was predicted. The results were confirmed by further experiments.