ADC12 박육 다이캐스팅 주물 내의 기포결함에 미치는 플런저 속도와 고속전환위치의 영향 (Effect of the Plunger Velocity and the Fast Shot Set Point on the Gas Porosity during ADC12 Plate Die Casting)

서지정보

· 발행기관 : 대한금속·재료학회
· 수록지 정보 : 대한금속·재료학회지 / 54권 / 2호 / 145 ~ 153페이지
· 저자명 : 강호정, 박진영, 김억수, 윤필환, 박익민

초록

A die casting process has been widely used in the manufacturing of automotive parts which require near-net shape casting and high productive rates. However, high-pressure die castings usually contain regions of gas porosity due mainly to the entrapment of air or gas in the die during the high-speed injection of molten metal into the die cavity. Gas porosity in castings has hampered the wider use of this method in the creation of high-durability automotive components. However, to establish a shot condition in the shot sleeve during the die casting process is critical, and difficulty remains when attempting to optimize the shot condition to avoid air entrapment effectively. In this study, ADC12 plate die castings were fabricated under various shot conditions, in which different plunger velocities and fast shot set points. In addition, according to the shot conditions, die casting experimental results were compared with an experiment involving a water model and with the results of a numerical analysis. The porosity of the castings was analyzed using CT and using density and microstructural analyses, and the effect of the porosity on the mechanical properties was analyzed using hardness and tensile testing. When the plunger velocity was 1.0 m/s and the fast shot set point is cavity 0, 25% position, the results with the castings were optimal, with good mechanical properties and few areas of porosity. In addition, the simulation results were mostly in agreement with die-casting experimental results.

영어초록

A die casting process has been widely used in the manufacturing of automotive parts which require near-net shape casting and high productive rates. However, high-pressure die castings usually contain regions of gas porosity due mainly to the entrapment of air or gas in the die during the high-speed injection of molten metal into the die cavity. Gas porosity in castings has hampered the wider use of this method in the creation of high-durability automotive components. However, to establish a shot condition in the shot sleeve during the die casting process is critical, and difficulty remains when attempting to optimize the shot condition to avoid air entrapment effectively. In this study, ADC12 plate die castings were fabricated under various shot conditions, in which different plunger velocities and fast shot set points. In addition, according to the shot conditions, die casting experimental results were compared with an experiment involving a water model and with the results of a numerical analysis. The porosity of the castings was analyzed using CT and using density and microstructural analyses, and the effect of the porosity on the mechanical properties was analyzed using hardness and tensile testing. When the plunger velocity was 1.0 m/s and the fast shot set point is cavity 0, 25% position, the results with the castings were optimal, with good mechanical properties and few areas of porosity. In addition, the simulation results were mostly in agreement with die-casting experimental results.

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