You can find a full list of discussed topics in our first post on the subject, by clicking here.

CASE STUDY CONSTRUCTION: Mechanical characteristics

The product we are going to study in today’s post is a door hinge. This mechanical component was designed to be subjected to medium-low stress intensity so, in contrast to other products in building sector, for this project esthetical characteristics were not relevant, while mechanical characteristics and resistance to wear were fundamental.

OBJECTIVE AND PHASES OF THE SIMULATION

The simulation objective was to minimize the defects that may influence mechanical characteristics of the door hinge: porosity and holes. The requirements for the component were:

• to be free of internal cavities and bubbles, caused by air entrapment, in the holes;
• to be filled correctly;
• no missing details;
• low shrinkage porosity both internally and in proximity of the feeders.

Thanks to previous experience in the production of similar pieces, our technicians knew that porosity is an extremely critical aspect for door hinges: the presence of holes and cavities, caused by the shrinkage of the part in proximity of the feeder, could reduce wear resistance and even cause the component to break when subjected to stress. In addition, incorrect cooling of the parts causes hot spots on the surface of the die, leading to the formation of cavities on the component surface.

The simulation analysis focuses mainly on the solidifying phase, with the objective of finding a configuration that allows homogeneous cooling of the part, thus avoiding the creation of hotter areas and prevent porosity.

RESULTS

The study of the filling phase focused on the analysis of the distribution of entrapped air. As you can see from the following picture, the quantity of air is minimal and evenly distributed in small amounts across the part.

Porosity is analyzed observing the behavior of the part during the solidifying phase: the most critical point is the feeder duct, where the alloy solidifies and contracts during cooling phase.

Contrary to the configuration used in similar parts that were previously made, where the feeder duct is perpendicular to the axis of the holes, in this simulation the duct is orientated parallel to the axis and its geometrical configuration is optimized to avoid the creation of hot spots on the part’s surface.

As can be observed in the image, in the new configuration the surface next to the feeders solidifies much more rapidly, subsequently diminishing the risk of shrinkage porosity thanks to the alloy flowing back into the feeder ducts or into the part itself.

The junction area solidifies quickly (colored in light blue), together with the rest of the product surface, lowering the surface porosity risk. The most critical area is the one right below the junction – as seen in the red circle – where the cooling is much slower because of the proximity to the feeder.

But as can be seen from the picture tagged “50% liquid”, the criticality should now be solved: the circled area is solid (colored in blue) while the core of the part is still liquid (colored in yellow).

The image above displays mold simulation: the part volume near the casting ingate leads to a really delayed solidification and to shrinking porosity as a direct consequence. In comparison, the junction re-positioning has reduced the issue of porosity thanks to a quicker cooling of molten metal.

The results of the simulation have been confirmed during the utilization of the die: the problem of shrinkage porosity, typical of this type of product, has been fully eliminated.

To sum up, the experience gained dealing with similar cases allowed Bruschi to identify the criticalities already in die designing phase and to study a solution through the use of simulation. The objective was to improve the resistance of the component by reducing shrinkage porosity: this makes the component more resistant to wear and prevents it from breaking under stress. The simulation study of solidification phase proved that placing the feeder duct parallel to holes’ axis increases cooling speed, thus reducing the risk of porosity.

Once again, this successful case study shows the importance of simulation in die casting: the application of new technologies can make a competitive difference on the market even in a millenarian industry such as metal working.

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The post Simulation for HPDC: shrinkage porosity case study appeared first on Bruschi.

Identifying cavities size, shape and surface, is crucial to point out which defect is occurring and to define its cause.

However it is important to distinguish shrinkage porosity from air entrapment: holes caused by air entrapment have rounded shapes, while lack of material of shrinkage porosity have angular surfaces.

For further information about air entrapment click on the previous link, otherwise continue reading.

Now let’s deeply analyze shrinkage porosity defect

How is shrinkage porosity caused?

Shrinkage porosity appears during material solidification phase, which begins with mold filling phase and ends when every part of the material is completely solidified. The cause of its creation is material shrink and, for this reason, porosity is as intense as shrink rate is high.

The metal injected inside the mold starts its cooling phase when it is in contact with walls. The thermal exchange with mold walls causes metal solidification from external surface to the core. During this phase metal volume decreases causing a convective gradient toward external surface. For this reason porosities are near inner and massive parts of the component.

In zinc high pressure die casting, in particular for zinc alloys die casting, shrink rate is really important.

Other characteristics of zinc HPDC that can amplify shrinkage porosity are zinc high thermal conductivity, small gate area of runners and not correct cooling of mold.

When mold design and operative parameters are not appropriate zinc alloys can solidify really quickly, thermal gradient can be  very high, hotspot could be generated and gates can be the first part of casting that solidify, in particular this last aspect leads to diminish compressing effect of stroke. This means shrinkage porosity.

Once analyzed these points, it is important to work on component geometry that is fundamental because some types of geometries can be more critical than others: for example heavy wall thickness and cross-sections too thick.

Shrinkage porosity in a new or already existent product

For a new product, in order to avoid defects, simulation analysis is necessary during design phase. If the component is already existing, it is necessary to test the mold and analyze castings affected by shrinkage porosity, in particular dimensions and defects position.

How to avoid defects with simulation for a new product

Shrinkage porosity can be eliminated ensuring the flow of liquid metal under high pressure during solidification phase. Specialists should use simulation software in order to obtain an analysis for casting solidification phase.

Strictly regarding shrinkage porosity with die casting simulation it is possible to identify shapes and locations of porosity and predict air entrapment tracking flows.

In high pressure die casting process, with die casting simulation tools, it is possible to optimize:

• Casting and molds geometry design
• Casting parameters
• Gating and cooling systems
• Die conformation

Data results are necessary to investigate the problem and to diagnose the process and predict defects.

How to fix shrinkage porosity for an existent product?

Sometimes it could happen that a supplier substitutes another supplier for a particular part. In general this can be for non-compliance issues for different reasons: one of these could be shrinkage porosity. In this case the new supplier has to work directly on products, trying to find the better solution.

For example if cavities have large dimensions and are always in the same position near gates, it could be necessary to act on different factors and in particular on runners and gates geometries. On the contrary if porosities have different frequencies and positions into casting, specialists should work on machines and operative parameters.

To avoid shrinkage porosity, for an existing part, it is possible to work in two different ways:

• Modifying die casting machines parameters
• Modifying the mold

Hereunder a focus to explain which changes are possible.

Modifying die casting machines parameters

Beforehand intervening on machine parameters it is important to check the correct functionality of it. In fact really often porosity issues can be caused by an incorrect or absent machine maintenance.

Once suppliers have verified the correct machine functionality, they can modify the following elements:

• Working pressure: increasing working pressure has always positive effects on shrinkage porosity issue, but it is important not to exceed machine locking force. To increase working pressure it is possible to decrease stroke diameter or increase hydraulic pressure.
• Working temperature: by modifying temperature and type of cooling fluid it is possible to cool down hotspots positioned in porosity zones.

Summarizing working pressure and temperature diminish porosity in terms of machines parameters.

Modifying the mold

Changing mold morphology means to avoid issues such as shrinkage porosity. Specialists can operate on:

• Feeding channel: if porosities are near injection gate the simplest and most effective way is to modify mold runner in order to slow down feeding channel solidification and increase compressing effect of stroke
• Cooling system: as for machine the aim is to reach porosities zones in order to cool down casting hotspots

Many benefits are given by these simulation software: for example less rejected products, shorten delivery time and improved quality. These predictions lead to significant cost reduction, improving material and energy consumption and reducing scraps.

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The post Shrinkage porosity: causes and remedies appeared first on Bruschi.