The Pore-Free Die Casting process (hereinafter referred to as PFD) is a special method in which die casting is accomplished by filling die cavities with oxygen gas, which easily combines chemically with molten metal to prevent gas bubbles in the product.
The PFD makes it possible to utilize pressure die casting to its maximum advantage and also to eliminate many disadvantages incurred by entrapped gas pores.
Nippon Light Metal Company, Ltd. started commercial production of aluminum wheels using the PFD process in 1982 and has also begun fabricating and marketing high quality magnesium products to meet the latest market requirements.
This paper will review the principle and technology of the PFD, and PFD application in automobile parts including light-weight wheel and other products.
The product characteristics such as mechanical properties, heat treatment, microstructure, internal quality, corrosion resistance, etc. of aluminum and magnesium castings made by the PFD will be described.