Study of the effect of process parameters on the production of a non-symmetric low pressure die casting part

Low pressure die-casting is a "near net shape" foundry process that offers a good compromise between economical aspects, production rate and casting quality. Because of the constrained position of the gating system, the application of traditional LPDC process is generally limited to axis-symmetric or symmetric geometries. The aim of this work was to investigate the low pressure die-casting process in order to define the effect of various system settings on the production of a sound non-conventional cast component. The research was supported by the modelling of mould filling and casting solidification, in order to evaluate both the influence of process parameters and the reliability of the modelling software in the prediction of flow pattern and thermal history of casting as well as defects formation. The results were compared with those obtained on an experimental die, completely instrumented, to better understand the process, validate the calculation procedure and make more confident the use of this tool for complex parts. Metallographic analyses were also carried out to compare the quality of simulated and real castings, with particular reference to shrinkage and gas porosity.