The material presented in this video are some highlights from NADCA’s online webinar - High Integrity Die Casting: Alloys for High Integrity Die Casting.
In this webinar all aspects of aluminum high integrity die casting alloys will be covered: from AA numbering, basic metallurgy, the role of alloying each element, impurities and their impact on part quality and properties, ... all the way to different alloy families and existing alloys currently used or under development, with their advantages and disadvantages, current and potential applications as well as achievable properties (using different heat treatments) with each of them. Learn more at the NADCA page.
For information on purchasing a downloadable copy of this webinar in its entirety, please visit: diecasting.org/store/detail.aspx?id=WEB143
(Transcript from the video highlight.)
"Let's talk about the role of each element. Of course, we have to start with silicon because most of our alloys are within the aluminum/silicon alloy family. So the more silicon we have, the better we get fluidity off the metal. And that's actually tricky because if you want perfect fluidity, you could basically just use pure aluminum. You would have very good fluidity. If you add silicon you first reduce it, but the more you add after that you increase it again.
And what's more important is really you get better castability. It reduces the shrinkage, improves hot tear resistance and feeding characteristics. That's what it's really all about. It also increases strength and stiffness. It reduces the specific gravity and coefficient of thermal expansion, which can in some cases be very useful. It improves pressure tightness and corrosion resistance of castings.
And of course, in hyper-eutectic alloys like the A390 or 391 alloy, it's used to increase wear resistance. So most of the die casting alloys really work with a 8% to 12% silicon level.
If we look at the phase diagrams, so we all know here it would be pure aluminum, and we're not going beyond the 20% silicon level. We're adding silicon. Here we go to the eutectic point, so that would be going from liquidness directly to solidness before we go through this mushy phase.
And we can see very easily all of those behaviors are plotted in a curve. So if I look at A, which is my fluidity, it first decreases. So if I use the 5% silicon alloy, I would have the worst fluidity of all aluminum silicon alloys. But then it increases again. If I want it to be as good as pure aluminum, I basically have to use the hyper-eutectic A390 alloy.
But again, I'm using this as a combination. So I'm using it to find the best point that I want to have as I'm looking at feeding behavior, for example. There I'm actually pretty high, if I'm going up here, and then shrinkage sensitivity, uniformity of shrinkage, and so on.
To purchase access to this course, visit the NADCA marketplace at www.diecasting.org/store. Purchasing a course through the online education system grants you one year of access to the recording, presentation, support material, and test, when applicable."
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