Analysis of Porosity Defects in Aluminum as Part Handle Motor Vehicle Lever Processed by High-pressure Die Casting

This research discusses the testing and analysis of cracking Aluminum (Al) material. Al as a handle lever was used for a braking device on a motor vehicle. Cracking of handle lever due to the part content of porosity from hydrogen gas. The existence of the H-2 can be caused by the casting process and dies design that is less perfect, especially at the gate or brisket and overflow. This research is to optimize the process of making Al part handle lever, and the construction dies by following the standard. The results of these improvements were re-evaluated through the chemical and mechanical testing properties stages, such as density test and tensile test on the workpiece as part handle lever. The loads on the tensile test are 25 kg and 35 kg, and the tensile test result has met the standard set by the motor vehicle company. The optimization result has the porosity defect can be reduced by 99 %. Therefore the best part handle lever can be produced.