2018 Volume 59 Issue 9 Pages 1471-1476
Die casting, a highly efficient production method, is widely applied to the manufacturing of automotive components. On the other hand, extending the die life is required to meet the needs of reducing the production cost because die costs are included in the manufacturing costs.
As one of the primary factors leading to die failures, soldering was investigated in this study by observing the adhesion of ADC12 alloy to the die and the reaction between ADC12 alloy and die in die casting process, analyzing the diffusion of concerned elements in ADC12 alloy, and numerically simulating the flow and the solidification of the molten metal. It was revealed that ADC12 alloy adhered to the surface of the die and caused the surface layer of the die castings to remain on the surface of the die by breaking the die castings with shearing stress at the time of ejection. In addition, Al–Si–Fe compounds were found at the interface between the die and the remaining ADC12 alloy layer with the repetition of die casting. These compounds grew gradually with the concentration of Si in the remaining ADC12 alloy layer towards the interface by diffusion with the further increase of shot numbers.
This Paper was Originally Published in Japanese in J. JFS 89 (2017) 757–763.