Mc Hpdc
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MC-HPDCMelt conditioned high pressure die casting
MC-HPDCMelt conditioned high pressure die casting
BCAST (Brunel Centre for Advanced Solidification Technology)
Brunel University
UK
MC-HPDC processMC-HPDC process
MC-HPDC = MCAST+ HPDC
MCAST
T/C
Inlet
T/C
HPDC Machine
HPDC vs. MC-HPDCHPDC vs. MC-HPDC
AD91D
HPDC
MC-HPDC
fs=0.31d=53
fs=0.32d=54
fs=0.32d=53
fs=0.30d=53
fs=0.32d=54
fs=0.32d=53
Uniform microstructure throughout the component (LM24)
Uniform microstructure throughout the component (LM24)
Property comparison Property comparison
125
150
175
200
225
250
275
0 2 4 6 8
Elongation (%)
UT
S (
MP
a)
HPDC
Thixo-cast
Thixo-moulded
MC-HPDC
AZ91D
Property comparison with other processes(357 alloy)
Property comparison with other processes(357 alloy)
240
250
260
270
280
290
300
310
0 2 4 6 8 10 12
Elongation (%)
UT
S (
MP
a)
New rheocasting (T5)Thixocasting (T5)MC-HPDC (F)MC-HPDC (T5)
Substantially increased fatigue lifeSubstantially increased fatigue life
AZ91D
10-3
10-2
10-1
100 101 102 103 104 105 106 107
Fatigue life (reversals)
Str
ain
am
pli
tud
e
HPDC 700oCMC+HPDC 630oC
MC+HPDC 587oC
LM24
10-3
10-2
10-1
100 101 102 103 104 105 106 107
Fatigue life (reversals)
Str
ain
am
pli
tud
e
HPDC 700oCMC+HPDC 630oC
MC+HPDC 587oC
LM24
Direct recycling of Mg scrapDirect recycling of Mg scrap
0
50
100
150
200
250
300
100%Scrap 50%Scrap Primary
Material Conditions
Yie
ld,
UT
S (
MP
a)
0
1
2
3
4
5
6
7
8
Elo
nga
tion
(%)
Yield UTS Elongation
AZ91D
Increased Fe tolerantIncreased Fe tolerant
2.0
2.5
3.0
3.5
4.0
0.0 0.5 1.0 1.5 2.0 2.5
Fe content (wt.%)
Elo
ngatio
n
(%)
RDC
HPDC
0.0
2.0
4.0
6.0
8.0
10.0
12.0
0.3 0.5 0.7 0.9 1.1 1.3Fe content (wt.%Fe)
Elo
ngation (
%)
RDC
HPDC
LM24(Al-9.3Si-3.2Cu-1.58Zn-0.3Mn)
LM25(Al-10.3Si-0.3Cu-0.16Mn)
Fe tolerance = 0.7wt% Fe tolerance = 0.37wt%
Advantages of MC-HPDC over HPDCAdvantages of MC-HPDC over HPDC
Increased fluidity and enhanced die filling due to dispersed oxide films and lumps of inclusions
Reduced melt temperature sensitivity
Reduced porosity (<0.5vol%) and well dispersed porosity
Reduced hot tearing
Fine and uniform microstructure throughout the entire component
Increased strength and ductility
Increased fatigue life
Direct recycling of scrap metal without degradation of properties
Increased tolerance to impurity elements
Increased range of die-castable alloys