DOI
10.5703/1288284318536
Description
Fluidity is a critical factor in high-pressure die casting (HPDC) of aluminum alloys, directly influencing mold filling behavior, defect formation, and the mechanical reliability of cast components. This study employs multiphase computational fluid dynamics (CFD) simulations to investigate how alloy composition, process parameters, and die conditions collectively affect molten metal flow and solidification dynamics. Key variables include viscosity, thermal conductivity, solidification range, pouring temperature, injection velocity, die geometry, and preheating temperature. Alloys with a narrow solidification range and lower thermal conductivity exhibit prolonged liquid-phase duration, which enhances flowability and reduces the risk of cold shuts and porosity. In contrast, increased magnesium content, reduced silicon and manganese levels, and wider solidification intervals tend to elevate viscosity and hinder fluid motion. Notably, alloys with silicon content near the eutectic point demonstrate superior fluidity due to optimized solidification behavior. JMatPro analysis further reveals that increasing magnesium promotes the formation of Mg₂Si phases, which significantly improves tensile strength and hardness. The overarching objective of this work is to design aluminum alloys that achieve high fluidity without compromising strength and ductility. By integrating melt front tracking, velocity field analysis, and thermal-fluid coupling, the simulations provide predictive insights into defect-prone regions and offer a framework for optimizing alloy design and HPDC process parameters in advanced manufacturing applications.
Integrated Simulation of Alloy Composition and Process Parameters for Fluidity Optimization in HPDC Aluminum Alloys
Fluidity is a critical factor in high-pressure die casting (HPDC) of aluminum alloys, directly influencing mold filling behavior, defect formation, and the mechanical reliability of cast components. This study employs multiphase computational fluid dynamics (CFD) simulations to investigate how alloy composition, process parameters, and die conditions collectively affect molten metal flow and solidification dynamics. Key variables include viscosity, thermal conductivity, solidification range, pouring temperature, injection velocity, die geometry, and preheating temperature. Alloys with a narrow solidification range and lower thermal conductivity exhibit prolonged liquid-phase duration, which enhances flowability and reduces the risk of cold shuts and porosity. In contrast, increased magnesium content, reduced silicon and manganese levels, and wider solidification intervals tend to elevate viscosity and hinder fluid motion. Notably, alloys with silicon content near the eutectic point demonstrate superior fluidity due to optimized solidification behavior. JMatPro analysis further reveals that increasing magnesium promotes the formation of Mg₂Si phases, which significantly improves tensile strength and hardness. The overarching objective of this work is to design aluminum alloys that achieve high fluidity without compromising strength and ductility. By integrating melt front tracking, velocity field analysis, and thermal-fluid coupling, the simulations provide predictive insights into defect-prone regions and offer a framework for optimizing alloy design and HPDC process parameters in advanced manufacturing applications.