Effect of vacuum on porosity and mechanical properties of high-pressure die-cast pure copper
Pure copper tensile bars were produced by conventional die casting (HPDC) and vacuum-assist die casting (VADC) processes. Porosity and mechanical properties were investigated by using optical microscopy (OM), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray computed to...
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| Published in | China foundry Vol. 16; no. 4; pp. 232 - 237 |
|---|---|
| Main Authors | , , , , , |
| Format | Journal Article |
| Language | English |
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Singapore
Springer Singapore
01.07.2019
Foundry Journal Agency Yunnan Copper Die-casting Technology Co., Ltd., Kunming 650001, China%School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, Beijing 100084, China Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, Beijing 100084, China%Yunnan Copper Die-casting Technology Co., Ltd., Kunming 650001, China School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China |
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| Abstract | Pure copper tensile bars were produced by conventional die casting (HPDC) and vacuum-assist die casting (VADC) processes. Porosity and mechanical properties were investigated by using optical microscopy (OM), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray computed tomography (XCT) and tensile tester. Results show that porosities including gas porosity and shrinkage porosity could be observed in copper castings. Since the application of vacuum could reduce filling related gas entrapment and facilitate solidification due to the increased heat transfer between metal and die, both number and size of the entrapped gases, as well as shrinkage porosities were significantly reduced in vacuum-assist die castings of pure copper. The porosity fraction decreased from 2.243% to 0.875% compared with that of the conventional die casting. Besides, mechanical properties were improved significantly, i.e., by 15% for ultimate tensile strength and three times for elongation. |
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| AbstractList | Pure copper tensile bars were produced by conventional die casting (HPDC) and vacuum-assist die casting (VADC) processes. Porosity and mechanical properties were investigated by using optical microscopy (OM), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray computed tomography (XCT) and tensile tester. Results show that porosities including gas porosity and shrinkage porosity could be observed in copper castings. Since the application of vacuum could reduce filling related gas entrapment and facilitate solidification due to the increased heat transfer between metal and die, both number and size of the entrapped gases, as well as shrinkage porosities were significantly reduced in vacuum-assist die castings of pure copper. The porosity fraction decreased from 2.243% to 0.875% compared with that of the conventional die casting. Besides, mechanical properties were improved significantly, i.e., by 15% for ultimate tensile strength and three times for elongation. TG146.1+1; Pure copper tensile bars were produced by conventional die casting (HPDC) and vacuum-assist die casting (VADC) processes. Porosity and mechanical properties were investigated by using optical microscopy (OM), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray computed tomography (XCT) and tensile tester. Results show that porosities including gas porosity and shrinkage porosity could be observed in copper castings. Since the application of vacuum could reduce filling related gas entrapment and facilitate solidification due to the increased heat transfer between metal and die, both number and size of the entrapped gases, as well as shrinkage porosities were significantly reduced in vacuum-assist die castings of pure copper. The porosity fraction decreased from 2.243% to 0.875% compared with that of the conventional die casting. Besides, mechanical properties were improved significantly, i.e., by 15% for ultimate tensile strength and three times for elongation. Pure copper tensile bars were produced by conventional die casting (HPDC) and vacuum-assist die casting (VADC) processes. Porosity and mechanical properties were investigated by using optical microscopy (OM), scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray computed tomography (XCT) and tensile tester. Results show that porosities including gas porosity and shrinkage porosity could be observed in copper castings. Since the application of vacuum could reduce filling related gas entrapment and facilitate solidification due to the increased heat transfer between metal and die, both number and size of the entrapped gases, as well as shrinkage porosities were significantly reduced in vacuum-assist die castings of pure copper. The porosity fraction decreased from 2.243% to 0.875% compared with that of the conventional die casting. Besides, mechanical properties were improved significantly, i.e., by 15% for ultimate tensile strength and three times for elongation. Key words: vacuum; copper; high pressure die casting (HPDC); mechanical properties; porosity CLC numbers: TG146.11 Document code: A Article ID: 1672-6421(2019)04-232-06 |
| Audience | Academic |
| Author | Pu, Zhou-meng Yang, Hong-mei Guo, Zhi-peng Xiong, Shou-mei Yang, Hua-zhong Fu, Zhi-hua |
| AuthorAffiliation | School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China;Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, Beijing 100084, China;Yunnan Copper Die-casting Technology Co., Ltd., Kunming 650001, China%School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China;Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, Beijing 100084, China%Yunnan Copper Die-casting Technology Co., Ltd., Kunming 650001, China |
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| Cites_doi | 10.1016/j.vacuum.2017.09.048 10.1016/S0924-0136(00)00545-8 10.1016/j.jallcom.2008.11.040 10.1016/j.scriptamat.2006.04.040 10.1016/j.jmatprotec.2015.12.005 10.1016/j.matchar.2016.02.007 10.1016/j.msea.2009.05.042 10.1016/j.scriptamat.2005.06.002 10.1109/ICElMach.2012.6349874 10.1007/s11661-013-1783-y 10.1017/S1431927615015172 10.1016/S1003-6326(14)63442-7 10.1016/j.jmst.2015.10.002 |
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| References | LiXXiongSCorrelation between porosity and fracture mechanism in high pressure die casting of AM60B alloyJournal of Materials Science & Technology2016321546110.1016/j.jmst.2015.10.002 Dale T P, John G C, Edwin F B. Die casting copper motor rotors: Mold Materials and Processing for Cost-Effective Manufacturing, 2000. LiXXiongSGuoZImproved mechanical properties in vacuum-assist high-pressure die casting of AZ91D alloyJournal of Materials Processing Technology20162311710.1016/j.jmatprotec.2015.12.005 YangZMaureyAKangJ2D and 3D characterization of pore defects in die cast AM60Materials Characterization201611425426210.1016/j.matchar.2016.02.007 Dale T P, John G C, Edwin F B, et al. Performance of motors with die-cast copper rotors in industrial and agricultural pumping applications: IEEE International Conference on Electric Machines & Drives, 2010: 987–992. BiswasSSketFMolinaCRelationship between the 3D porosity and beta-phase distributions and the mechanical properties of a high pressure die cast AZ91 Mg alloyMetallurgical & Materials Transactions A20134494391440310.1007/s11661-013-1783-y Edwin F B, Stephen P M, Walkington W G, et al. Porosity control in copper rotor die castings. In: Proceedings of North American Die Casting Association Congress, Indianapolis, 2003. HarshitaA PRashidiNChenDCyclic deformation behavior of a super-vacuum die cast magnesium alloyMaterials Science & Engineering A201254637281 LiWHuZWuSMechanical properties and fatigue behavior of vacuum-assist die cast AlMgSiMn alloyMaterials Science & Engineering A20135768252258 WangQXiongSVacuum assisted high-pressure die casting of AZ91D magnesium alloy at different slow shot speedsTransactions of Nonferrous Metals Society of China2014241030513059321192710.1016/S1003-6326(14)63442-7 Liang Dong, Yang Xu, Yu Jiabin, et al. Experience in China on the die-casting of copper rotors for induction motors. In: Proceedings-2012 20th International Conference on Electrical Machines, 2013: 256–260. NiuXHuBIanE PVacuum assisted high pressure die casting of aluminium alloysJournal of Materials Processing Technology2000105111912710.1016/S0924-0136(00)00545-8 SoonG LGautamR PGokhaleA MVariability in the tensile ductility of high-pressure die-cast AM50 Mg alloyScripta Materialia200553785185610.1016/j.scriptamat.2005.06.002 András B, Walter B. Two frequently development ways of induction motors: high efficiency and high-speed drives. 4th International Conference on Magnetism and Metallurgy, 2018: 387–391. JiangWCaoZXuSThree-dimensional microstructure reconstruction and finite element simulation of gas pores in the high-pressure die-casting AZ91 Mg alloyMicroscopy & Microanalysis20152161420142510.1017/S1431927615015172 SoonG LGokhaleA MFormation of gas induced shrinkage porosity in Mg-alloy high-pressure die-castingsScripta Materialia200655438739010.1016/j.scriptamat.2006.04.040 SongJXiongSLiMThe correlation between microstructure and mechanical properties of high-pressure die-cast AM50 alloyJournal of Alloys & Compounds2009477186386910.1016/j.jallcom.2008.11.040 SongJXiongSLiMIn situ observation of tensile deformation of high-pressure die-cast specimens of AM50 alloyMaterials Science & Engineering A2009520119720110.1016/j.msea.2009.05.042 FrancescoPMarcoVDesign of high efficiency induction motors with die-casting copper rotors2003Berlin, HeidelbergSpringer144151 CaoHHaoMShenCThe influence of different vacuum degree on the porosity and mechanical properties of aluminum die castingVacuum201714627828110.1016/j.vacuum.2017.09.048 SoonG LGautamR PGokhaleA MQuantitative fractographic analysis of variability in the tensile ductility of high-pressure die-cast AE44 Mg-alloyMaterials Science & Engineering A20064271255262 Q Wang (9036_CR17) 2014; 24 Z Yang (9036_CR18) 2016; 114 J Song (9036_CR10) 2009; 477 9036_CR2 9036_CR3 G L Soon (9036_CR8) 2005; 53 W Jiang (9036_CR21) 2015; 21 J Song (9036_CR11) 2009; 520 A P Harshita (9036_CR13) 2012; 546 H Cao (9036_CR20) 2017; 146 W Li (9036_CR14) 2013; 576 X Li (9036_CR9) 2016; 32 P Francesco (9036_CR1) 2003 9036_CR6 G L Soon (9036_CR7) 2006; 427 X Niu (9036_CR15) 2000; 105 9036_CR4 9036_CR5 S Biswas (9036_CR12) 2013; 44 G L Soon (9036_CR19) 2006; 55 X Li (9036_CR16) 2016; 231 |
| References_xml | – reference: Edwin F B, Stephen P M, Walkington W G, et al. Porosity control in copper rotor die castings. In: Proceedings of North American Die Casting Association Congress, Indianapolis, 2003. – reference: SoonG LGautamR PGokhaleA MVariability in the tensile ductility of high-pressure die-cast AM50 Mg alloyScripta Materialia200553785185610.1016/j.scriptamat.2005.06.002 – reference: LiXXiongSCorrelation between porosity and fracture mechanism in high pressure die casting of AM60B alloyJournal of Materials Science & Technology2016321546110.1016/j.jmst.2015.10.002 – reference: FrancescoPMarcoVDesign of high efficiency induction motors with die-casting copper rotors2003Berlin, HeidelbergSpringer144151 – reference: Dale T P, John G C, Edwin F B, et al. Performance of motors with die-cast copper rotors in industrial and agricultural pumping applications: IEEE International Conference on Electric Machines & Drives, 2010: 987–992. – reference: Liang Dong, Yang Xu, Yu Jiabin, et al. Experience in China on the die-casting of copper rotors for induction motors. In: Proceedings-2012 20th International Conference on Electrical Machines, 2013: 256–260. – reference: LiWHuZWuSMechanical properties and fatigue behavior of vacuum-assist die cast AlMgSiMn alloyMaterials Science & Engineering A20135768252258 – reference: JiangWCaoZXuSThree-dimensional microstructure reconstruction and finite element simulation of gas pores in the high-pressure die-casting AZ91 Mg alloyMicroscopy & Microanalysis20152161420142510.1017/S1431927615015172 – reference: SongJXiongSLiMThe correlation between microstructure and mechanical properties of high-pressure die-cast AM50 alloyJournal of Alloys & Compounds2009477186386910.1016/j.jallcom.2008.11.040 – reference: Dale T P, John G C, Edwin F B. Die casting copper motor rotors: Mold Materials and Processing for Cost-Effective Manufacturing, 2000. – reference: HarshitaA PRashidiNChenDCyclic deformation behavior of a super-vacuum die cast magnesium alloyMaterials Science & Engineering A201254637281 – reference: SoonG LGautamR PGokhaleA MQuantitative fractographic analysis of variability in the tensile ductility of high-pressure die-cast AE44 Mg-alloyMaterials Science & Engineering A20064271255262 – reference: SoonG LGokhaleA MFormation of gas induced shrinkage porosity in Mg-alloy high-pressure die-castingsScripta Materialia200655438739010.1016/j.scriptamat.2006.04.040 – reference: NiuXHuBIanE PVacuum assisted high pressure die casting of aluminium alloysJournal of Materials Processing Technology2000105111912710.1016/S0924-0136(00)00545-8 – reference: YangZMaureyAKangJ2D and 3D characterization of pore defects in die cast AM60Materials Characterization201611425426210.1016/j.matchar.2016.02.007 – reference: LiXXiongSGuoZImproved mechanical properties in vacuum-assist high-pressure die casting of AZ91D alloyJournal of Materials Processing Technology20162311710.1016/j.jmatprotec.2015.12.005 – reference: CaoHHaoMShenCThe influence of different vacuum degree on the porosity and mechanical properties of aluminum die castingVacuum201714627828110.1016/j.vacuum.2017.09.048 – reference: András B, Walter B. Two frequently development ways of induction motors: high efficiency and high-speed drives. 4th International Conference on Magnetism and Metallurgy, 2018: 387–391. – reference: WangQXiongSVacuum assisted high-pressure die casting of AZ91D magnesium alloy at different slow shot speedsTransactions of Nonferrous Metals Society of China2014241030513059321192710.1016/S1003-6326(14)63442-7 – reference: SongJXiongSLiMIn situ observation of tensile deformation of high-pressure die-cast specimens of AM50 alloyMaterials Science & Engineering A2009520119720110.1016/j.msea.2009.05.042 – reference: BiswasSSketFMolinaCRelationship between the 3D porosity and beta-phase distributions and the mechanical properties of a high pressure die cast AZ91 Mg alloyMetallurgical & Materials Transactions A20134494391440310.1007/s11661-013-1783-y – volume: 146 start-page: 278 year: 2017 ident: 9036_CR20 publication-title: Vacuum doi: 10.1016/j.vacuum.2017.09.048 – volume: 427 start-page: 255 issue: 1 year: 2006 ident: 9036_CR7 publication-title: Materials Science & Engineering A – volume: 105 start-page: 119 issue: 1 year: 2000 ident: 9036_CR15 publication-title: Journal of Materials Processing Technology doi: 10.1016/S0924-0136(00)00545-8 – volume: 477 start-page: 863 issue: 1 year: 2009 ident: 9036_CR10 publication-title: Journal of Alloys & Compounds doi: 10.1016/j.jallcom.2008.11.040 – volume: 546 start-page: 72 issue: 3 year: 2012 ident: 9036_CR13 publication-title: Materials Science & Engineering A – volume: 55 start-page: 387 issue: 4 year: 2006 ident: 9036_CR19 publication-title: Scripta Materialia doi: 10.1016/j.scriptamat.2006.04.040 – volume: 231 start-page: 1 year: 2016 ident: 9036_CR16 publication-title: Journal of Materials Processing Technology doi: 10.1016/j.jmatprotec.2015.12.005 – volume: 114 start-page: 254 year: 2016 ident: 9036_CR18 publication-title: Materials Characterization doi: 10.1016/j.matchar.2016.02.007 – volume: 520 start-page: 197 issue: 1 year: 2009 ident: 9036_CR11 publication-title: Materials Science & Engineering A doi: 10.1016/j.msea.2009.05.042 – volume: 53 start-page: 851 issue: 7 year: 2005 ident: 9036_CR8 publication-title: Scripta Materialia doi: 10.1016/j.scriptamat.2005.06.002 – volume: 576 start-page: 252 issue: 8 year: 2013 ident: 9036_CR14 publication-title: Materials Science & Engineering A – ident: 9036_CR4 doi: 10.1109/ICElMach.2012.6349874 – volume: 44 start-page: 4391 issue: 9 year: 2013 ident: 9036_CR12 publication-title: Metallurgical & Materials Transactions A doi: 10.1007/s11661-013-1783-y – volume: 21 start-page: 1420 issue: 6 year: 2015 ident: 9036_CR21 publication-title: Microscopy & Microanalysis doi: 10.1017/S1431927615015172 – ident: 9036_CR5 – ident: 9036_CR3 – ident: 9036_CR2 – ident: 9036_CR6 – volume: 24 start-page: 3051 issue: 10 year: 2014 ident: 9036_CR17 publication-title: Transactions of Nonferrous Metals Society of China doi: 10.1016/S1003-6326(14)63442-7 – start-page: 144 volume-title: Design of high efficiency induction motors with die-casting copper rotors year: 2003 ident: 9036_CR1 – volume: 32 start-page: 54 issue: 1 year: 2016 ident: 9036_CR9 publication-title: Journal of Materials Science & Technology doi: 10.1016/j.jmst.2015.10.002 |
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| Snippet | Pure copper tensile bars were produced by conventional die casting (HPDC) and vacuum-assist die casting (VADC) processes. Porosity and mechanical properties... TG146.1+1; Pure copper tensile bars were produced by conventional die casting (HPDC) and vacuum-assist die casting (VADC) processes. Porosity and mechanical... |
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| SubjectTerms | Analysis CAT scans copper Copper (Metal) Electron microscopy Engineering high pressure die casting (HPDC) Machines Manufacturing Materials Engineering Mechanical properties Metallic Materials Microscopy Porosity Processes Research & Development Spectroscopy Tomography vacuum |
| Title | Effect of vacuum on porosity and mechanical properties of high-pressure die-cast pure copper |
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