Effect of Si, Cu and processing parameters on Al-Si-Cu HPDC castings

Chemical composition of secondary Al-Si-Cu alloys and working variables of high-pressure die casting process (HPDC) may change for the same casting parts from one country to another in the world. They can even sometimes vary from one manufacturing site to another within the same country. An experimental study on the influence of alloying elements contents (Si and Cu), casting temperature and injection pressure on mechanical properties of die cast aluminum alloys was carried out to support the automotive industry suppliers in designing their cast parts. The microstructural features and the porosity level were also investigated and assessed. The primary objective is to highlight the modification mechanisms of the achieved properties using tensile tests, hardness measurements and microstructural observations performed on a HPDC casting parts. Low pressure and low temperature increase the rate of porosity, promote the formation of coarse Fe-rich intermetallic compounds and change the morphology of alpha-Al phases. These in turn deteriorate mechanical tensile properties. However, variation of alloying elements contents modifies the optimum properties achieved when part is made at constant casting processing parameters. Finally, the interactions between the studied parameters of HPDC and the chemical alloying elements show also a significant influence on the tensile properties.