Parametric Analysis of Cold Chamber High Pressure Die Casting of LM9 and ADC12 Aluminium Alloys

Abstract

High pressure die casting (HPDC) is a favorable manufacturing process for casting of aluminium and magnesium alloys components like gear-box, piston, cylinder, transmission cover, laptop housing etc. HPDC used in the current study is applied for casting the thin walls as well as components of intricate shapes. The final machining and finishing operation on components produced using HPDC are negligible. Higher production volume, higher dimensional accuracy and better surface finish with required tolerances can be achieved by using high pressure die casting. Experimental investigation and property analysis is carried out in the present work. Response surface methodology has been used to develop the input output relations. Pouring temperature of molten metal, injection pressure, die holding time and die coating have been considered as input parameters while density, hardness and surface roughness have been considered as output parameters. LM9 and ADC12 aluminium alloys have been used as raw materials. Experimental work has been carried out on cold chamber high pressure die casting machine. Based on experiments carried out, Box-Behnken design technique has been used to develop nonlinear models. Surface morphology has been also studied using scanning electron microscopy.