Temperature Development of an AlSi9Cu3 Aluminum Alloy During and After Die Casting

Abstract This publication analyzes the influence of cooling rate on the solid solution state during and after die casting of the AlSi9Cu3 alloy and, based on simulation and experimental results, predicts the R p0.2 yield strength as a function of cooling rate. The subject of the investigation is a four-cylinder in-line engine cast using the laminar die casting process. The implementation of a thermocouple in the casting mold enables in-situ measurement of the temperature-time behavior during the casting process, from filling the mold to demolding the component. Based on this measurement, the heat transfer coefficient between the casting mold and the melt is validated in the Magmasoft® casting simulation. The temperature-time behavior after demolding is reproduced using a specific test setup. The temperature measurements taken enable the existing casting simulation in Magmasoft® to be extended to the quenching process outside the casting mold. The correlation of the results of the tensile tests from the crankcase with the determined cooling rates enables the prediction of the R p0.2 yield strength as a function of the temperature-time behavior for the application of laminar die casting.