The hard-spot which often appears on the overflow side of Al alloy pressure die castings, has a chilled Al alloy structure.
The purpose of this report is to explain the mechanism for the occurrence of hard-spots, by examining the structure of the various parts of pressure die castings, under the assumption that there is a close relation between the structure of hard spots and that of die castings, after comparing the microscopic structure of pressure die castings with that of "Isolite" castings.
The results obtained from gravity die castings and this research are as follows:
1. Hard spots appeared again on the remelted and recast products which had previously had hard spots.
2. The microscopic structure of pressure die castings was very subtle with fine contained particles. α-Al crystals were ill balanced to form a unique structure.
3. In 150 times enlarged photographs under a microscope, the structure of die castings was more fine in the nearer part to the overflow side or the other side of the gate, where the components were partially concentrated to form their blocks. When these blocks come out apparently distinct from the other parts, they are called hard spots. In 600 times enlarged microscopic pictures, the particles of the contained elements were also more fine in the nearer part to the overflow side, where the particles of Si were granulated.
The conclusion reached through the above-mentioned results would be as follows:
In the manufacture of pressure die castings with complicated shapes, the molten metal injected into the dies, hits the inside wall of the dies and scatters. The scattered molten metal hits the inside wall and scatters again. The molten metal is cast and solidified in this process of repeated scattering. The components of the alloy which has been cooled down in this process, are segregated as groups by such mechanical actions as centrifugal separation.
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