The Use of Quality Mapping to Predict Performance of Thin-Walled Magnesium Die Castings

A methodology that includes the processing history of the metal in the High Pressure Die Casting (HPDC) process in the simulations of the structural behavior of magnesium components has been established. In this methodology the results from the HPDC process simulations are used to modify the material model and the fracture criterion in the Finite Element Analysis (FEA). This paper focuses on the simulation of the HPDC process for thin-walled magnesium components. The close connection between the processing history and the mechanical properties of the casting mandates a careful analysis of the key factors influencing the final part performance. The definition of the boundary and initial conditions will strongly influence the ability to predict important features in the microstructure of the casting and consequently the final mechanical properties of the casting. In this context, improvements in HPDC process simulations are important in order to improve the predictability of the FEA of the final part performance.