The purpose of this study was not only to statistically analyse the origin of the casting blow-hole formation for zinc and aluminum alloys but also to consider preventive methods for it. The multiple correlation analysis was used in the statistical examination.
From the analysis of the experimental results it was found that the factors influencing the formation of casting blow-holes were pouring time, pouring temperature, amount of parting agent, thermal decomposition ratio, thermal decomposition rate and injection conditions. The multiple correlation coefficient for these factors obtained from the amount of gas in the cavity, the amount of parting agent and the injecting condition was estimated to be 0.9 regardless of the kinds of alloys.
The air and gas in the cavity did not disperse outside because they were wrapped up in the molten metal being injected with high speed and high pressure, and resulted in the formation of the casting blow-hole. Thus it was considered that to prevent these troubles a flow of these gases should be lead out towards a certain direction. Three methods to take the gas in the cavity out which are the pressure reduction method, the blowing gas method and the method combining the two previous methods were employed in this die-casting experiment for ZnDC 2 and ADC 12 alloys.
In the case of the pressure reduction method, gas in the cavity flowed into the pressure reducing tank connected to the vent hole of dies. In the flowing gas method, gas in the cavity flowed outside through the vent hole passing a constant flow of gas from the pouring hole. In the method combining the two methods, the gas flowing into cavity were immediately evacuated with the pressure reducing tank.
The results obtained by these developing techniques of die-casting in this experiment are summarized as follows.
(1) As compared with an conventional die casting method, it was easy to prevent the die-casting blow-hole formation with this method.
(2) The tensile strengh of castings produced by this method was 10-15% higher than that by a conventional method.
(3) The castings produced was confirmed to withstand heat treatment and facilitate surface polishing.
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