Optimization of die casting conditions for wear properties of alloy AZ91D components using the Taguchi method and design of experiments analysis

This investigation applied the Taguchi method and designs of experiments (DOE) approach to optimize parameters for magnesium alloy AZ91D. Tribological properties of wear mass loss and friction coefficients were studied. Planning of experiments was based on a Taguchi orthogonal array table, and applied signal-to-noise ratios to determine an optimal setting. Furthermore, as the analysis of variance (ANOVA) was adapted to identify the most influential factors, the fusion slurry pressure was found to be the most significant factor. By applying regression analysis, a mathematical predictive model of the wear mass loss was developed in terms of the die casting process parameters. Additional runs were conducted in order to validate the optimal setting and compare the performance of the Taguchi method and the DOE approach. In this study, the wear mechanisms of adhesive and delamination for the AZ91D were found through wear tests. A specimen with a low wear mass loss has shown a low friction coefficient as well as small exfoliates and fractures.