Effect of Piston Velocity on Microstructural Consistency and Critical Regions in a High-Pressure Die Cast AlSi9Cu3(Fe) Alloy Component

High-pressure die casting (HPDC) is a highly efficient method for producing aluminum parts that require high dimensional accuracy and complex shapes. However, the quality of the resulting castings, specifically their porosity and microstructure, is critically dependent on the setting of process parameters. Any deficiencies in these aspects can lead to a significant reduction in the mechanical properties of the components. This article deals with the influence of plunger speed during high-pressure die casting on microstructure homogeneity and the occurrence of porosity in critical areas of AlSi9Cu3(Fe) alloy castings. Numerical simulations and experimental evaluation demonstrated that with increasing plunger speed, there is a transition from a transitional to a laminar flow regime to a fully turbulent regime, which affects the homogeneity of the alloy and its solidification. Turbulent flow minimizes shrinkage porosity in castings but increases the risk of gas porosity and oxide inclusions due to reoxidation processes, leading to the entrainment of air and oxide layers. Microporosity analysis showed that the lowest occurrence of shrinkage-type pores was found at a plunger speed of 4 m/s due to rapid filling and shorter solidification time. The optimal plunger speed range is between 3 and 3.6 m/s, ensuring a compromise between microstructure stability and minimization of porosity in critical areas.