The effect of high pressure die casting process characteristics on the properties and performance of advanced MG alloys

High-pressure die-casting is the leading process technology for the mass production of magnesium components with complex configurations having typical thin to medium wall thickness. The growing use of die cast magnesium alloys for the automotive industry, particularly for the production of drive train applications, has lead to the development of new advanced die casting alloys with improved creep resistance, namely MRI 153M and MRI 230D. MRI 153M alloy has a long-term operation at temperatures up to 150°C under high loads. MRI 230D is a die cast alloy that was developed to address powertrain applications operating at temperatures up to 190°C. The alloy has excellent creep resistance combined with good castability, high strength and superior corrosion behavior. The aim of the present paper is to establish semi-empiric correlations between the HPDC parameters, the solidification characteristics and the properties of the die cast component. The paper includes comprehensive investigation of the heat transfer and energy balance during the die casting process. The above should be implemented in order to obtain reliable part design as well as optimized process characteristics for the production of sound, high quality die cast applications.