Porosity reduction possibilities in commercial Aluminium A380 and Magnesium AM60 alloy components using the RheoMetalTM process

Abstract

A commercial component was produced from
both aluminium A380 (EN AC 46000) and
magnesium AM60 alloys by high pressure die
casting (HPDC) and rheocasting using the
RheoMetal process. This process, which is
based on the Rapid Slurry Forming (RSF)
technology, is capable of producing large
amounts of metal slurries in short times. The
aim of this paper is to investigate the
possibility to reduce porosity, and the
related effects on the tensile properties
obtained in RSF rheocast components.
Significantly reduced pore content was
obtained in the RSF rheocast A380 and
AM60 alloy components, as compared to the
HPDC components. This was confirmed by Xray
analysis, microstructure analysis and on
polished component sections. The turbulent
filling behaviour in HPDC produces severe
amounts of entrained gas type porosity. It was
also found that gas pores often were
connected to shrinkage type pores.