This paper provides a description of commercially available die casting processes including conventional die casting process (high pressure, high velocity), squeeze casting (high pressure, controlled cavity fill rate), semi-solid metal casting, and Vacural™ (a variation of the conventional die casting process). The various automotive products made using these processes are also reported in the study.
In this study, the mechanical (tensile, impact, fatigue strength and fracture toughness) and wear properties are compared among the above processes. Results indicate that mechanical and wear properties of aluminum alloys made using the “high integrity” casting processes (squeeze, semi-solid metal casting and Vacural™) are superior to those of conventional die castings.
Finally, cavitation erosion (mechanical degradation of materials caused by cavitation in liquids) data for select aluminum alloys commonly used in squeeze casting and semi-solid metal casting processes are reported in this study. Results show that the type of casting process used, surface finish and alloy chemistry are key factors influencing erosion wear.