Mechanism and preventive measures for die soldering during Al casting in a ferrous mold

This work provides a comprehensive understanding of the reactions at the ferrous die/molten metal interface in a metal mold casting operation. The literature has shown that several important factors influence reactions at the ferrous die/molten aluminum interface, including temperature of the melt, temperature of the die, alloy chemistry of the melt and die, die surface engineering, topographical features, and coatings. This article discusses the effect of the more critical factors on soldering, based on the authors' investigations. In addition, based on a mechanistic understanding of the interface reactions between ferrous die and molten aluminum, recommendations are given for specific processing issues to alleviate soldering during die casting of aluminum alloys.