The Local Squeeze Technology for Challenging Aluminium HPDC Automotive Components

A key issue in producing high-quality aluminium automotive components by the High-Pressure Die Casting process (HPDC) is minimizing the defects. For the HPDC technology, the wall thickness of components needs to be monitored because it dramatically affects the grain size and porosity appearance. In this work, local squeeze technology is used in aluminium high-pressure die casting. The aim is to optimize quality in thick sections of complex geometries, where designers cannot modify components' features and the casting process cannot solve shrinkage porosities with the state-of-the-art process control, like intensification pressure or cooling management. The present paper relates to a study of the squeeze pin effect on HPDC aluminium parts, where material homogeneity for leak prevention is a must. Both product and process development for reliable industrialization of the local squeeze technology will be covered, from casting virtual simulation to the metallurgical analysis of the affected area. The affected area was analyzed by means of to understand the local squeeze effect on microstructures.