Characterization of Melt Flow During High-Pressure Die Casting Using Layered, Inorganically Bonded Sand Cores

Abstract High-pressure die casting (HPDC) is a key process for producing thin-walled aluminum components. However, the extreme dynamics of mold filling have so far limited direct visual access. As a result, most insights into melt flow rely on numerical simulations, while high-resolution validation data under real HPDC conditions are scarce. In this study, a specially designed die with an integrated observation window enabled high-speed imaging of aluminum melt flow during cavity filling. Gate velocities between 30 m/s and 60 m/s and different gating system designs were investigated to analyze their influence on flow symmetry, splash formation, and the flow interaction with inserted multilayered, inorganically bonded sand cores. Although the methodology was originally developed for studying such advanced cores, the present work focuses on characterizing the melt flow behavior, and the cores therefore serve only as functional inserts. The recordings revealed distinct effects of gating geometry and plunger velocity. Comparison with MAGMASOFT ® mold filling simulations showed good qualitative agreement in global flow patterns, though fine details such as spray formation were less accurately captured. These results provide direct visualization of melt flow under realistic HPDC conditions, establishing a valuable basis for simulation validation.