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high thermal conductivity and high strength magnesium alloy for high pressure die casting ultrathin-walled components

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International Journal of Minerals,Metallurgy and Materials 2022年第1期29卷 88-96页

作者： Jian Rong Wenlong Xiao Xinqing Zhao Chaoli Ma Haimiao Liao Donglei He Ming Chen Meng Huang Chen Huang Key Laboratory of Aerospace Advanced Materials and Performance of Ministry of Education School of Materials Science and EngineeringBeihang UniversityBeijing 100191China Dongguan Qingniao Metal Material Co. Ltd.Dongguan 523000China Structural Technology Department Hardware Technology CenterOPPO Guangdong Mobile Communications Co.Ltd.Dongguan 523000China

With the rapid development of 3C industries,the demand for high-thermal-conductivity magnesium alloys with high mechanical performance is increasing ***,the thermal conductivities of most common Mg foundry alloys(such as Mg-9wt%-1wt%Zn)are still relatively *** this study,we developed a high-thermal-conductivity Mg-4Al-4Zn-4RE-1Ca(wt%,AZEX4441)alloy with good mechanical properties for ultrathin-walled cellphone components via high-pressure die casting(HPDC).The HPDC AZEX4441 alloy exhibited a fine homogeneous microstructure(average grain size of 2.8μm)with granular Al_(11)RE_(3),fibrous Al_(2)REZn_(2),and networked Ca_(6)Mg_(2)Zn_(3) phases distributed at the grain *** room-temperature thermal conductivity of the HPDC AZEX4441 alloy was 94.4 W·m^(-1)·K^(-1),which was much higher than 53.7 W·m^(-1)·K^(-1) of the HPDC AZ91D *** and Zn in the AZEX4441 alloy were largely consumed by the formation of Al_(11)RE_(3),Al_(2)REZn_(2),and Ca_(2)Mg_(6)Zn_(3) phases because of the addition of RE and ***,the lattice distortion induced by solute atoms of the AZEX4441 alloy(0.171%)was much lower than that of the AZ91D alloy(0.441%),which was responsible for the high thermal conductivity of the AZEX4441 *** AZEX4441 alloy exhibited a high yield strength of~185 MPa,an ultimate tensile strength of~233 MPa,and an elongation of~4.2%.This result indicated that the tensile properties were comparable with those of the AZ91D ***,this study contributed to the development of high-performance Mg alloys with a combination of high thermal conductivity,high strength,and good castability.

关键词： magnesium alloys microstructure thermal conductivity mechanical properties high-pressure die casting

The microstructure characteristics and fracture behavior of the polyhedral primary iron-rich phase and plate-shaped eutectic iron-rich phase in a high-pressure die-cast AlSi10MnMg alloy

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Journal of Materials Science & Technology 2023年第9期140卷 201-209页

作者： X.Y.Jiao Y.X.Liu J.Wang W.N.Liu A.X.Wan Stuart Wiesner S.M.Xiong School of Materials Science and Engineering Northeastern UniversityShenyang 110819China School of Materials Science and Engineering Tsinghua UniversityBeijing 100084China Key Laboratory of Lightweight Structural Materials Liaoning ProvinceNortheastern UniversityShenyang 110819China Key Laboratory for Advanced Materials Processing Technology Tsinghua UniversityBeijing 100084China Shanghai Synchrotron Radiation Facility Shanghai Advanced Research InstituteChinese Academy of SciencesShanghai 201204China Ein Unternehmen der ALUMINIUM RHEINFELDEN Group RHEINFELDEN 79618Germany

The characterization of multiple iron-rich phases in high-pressure die-cast AlSi10MnMg alloy was *** was focused on the formation and fracture behavior of the primary iron-rich phase((P-IMC)_(I))formed in the shot sleeve and plate-shaped eutectic iron-rich phase in high-pressure die cast(HPDC)AlSi10MnMg *** show that multiple types of iron-rich phases with various morphologies,in-cluding primary iron-rich phases(polyhedral(P-IMC)_(I) and(P-IMC)_(II))and eutectic iron-rich phases(plate-shaped,net shape,and fish-bone shape),were found in HPDC ***(P-IMC)_(I) formed in the shot sleeve were distributed in the interface between primaryα-Al and binary Al-Si *** size(P-IMC)_(II) and various eutectic iron-rich phases formed in the die cavity and they were distributed in Al-Si binary *** primary iron-rich phases belonged to a simple cubic crystal structure with a lattice constant a=1.265 nm and they exhibited a lateral growth characteristic with a termination of{110}surface.βphase was surrounded byδphase and they coexisted in a plate-shaped iron-rich ***-density stacking fault inβphase andδ/βinterface provided an excellent nucleation site forδ*** mechanical behavior,the stress concentration caused by eutectic iron-rich phases was far less than(P-IMC)_(I) and it would not cause crack initiation along the eutectic cluster *** addition,(P-IMC)_(I) showed the worst deformation coordination with primaryα-Al while the plate-shaped eutectic iron-rich phase exhibited similar deformation characteristics with silicon particles.

关键词： AlSi10MnMg high-pressure die casting Multiple iron-rich phases

Effects of runner design and pressurization on the microstructure of a high-pressure die cast Mg-3.0Nd-0.3Zn-0.6Zr alloy

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International Journal of Minerals,Metallurgy and Materials 2022年第7期29卷 1310-1316页

作者： Tongtong Zhang Wenbo Yu Chaosheng Ma Yuqi Zhou Shoumei Xiong Center of Materials Science and Engineering School of Mechanical and Electronic Control EngineeringBeijing Jiaotong UniversityBeijing 100044China School of Materials Science and Engineering Tsinghua UniversityBeijing 100084China

To clarify the relationship between externally solidified crystals(ESCs)and other defects,e.g.,defect bands and pores,two dimensional(2D)and three dimensional(3D)characterization methods were adopted to analyze castings produced using a modified ingate system equipped with and without an ESC *** reduction of ESCs strongly reduced defect band width and shrinkage pore *** reducing the quantity and size of ESCs,net-shrinkage pores were transformed into isolated island-shrinkage *** determined via statistical analysis that the mechanical properties of high pressure die castings were strongly related to the size and fraction of the ESCs rather than porosity *** reduction of ESCs also caused tensile transgranular fracture modes to transform into intergranular fracture ***,casting pressurization strongly reduced pore morphology,volume,and size.

关键词： high-pressure die casting externally solidified crystals porosity 3D reconstruction runner design

Microstructure,Mechanical Properties and die-Filling Behavior of high-Performance die-Cast Al-Mg-Si-Mn Alloy

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Acta Metallurgica Sinica(English Letters) 2015年第11期28卷 1344-1353页

作者： Zu-Qi Hu Xin-Jian Zhang Shu-Sen Wu Institute of Materials China Academy of Engineering Physics State Key Lab of Materials Processing and die & Mould Technology Huazhong University of Science and Technology

This work aims to reveal the relationships between the microstructure, mechanical properties and flow behavior of die-casting AlMg5Si2Mn alloy. Results indicated that the microstructure of the die-cast AlMgsSi2Mn consists of α1-Al grains, fine-size α2-Al grains and （Al ＋ Mg2Si） eutectic. The surface layer observed has the thickness in a range of 120-135 μm, while an ellipse-like surface layer edge is observed in the corner of the plateqike sample. Tensile strength and elongation （3） of the specimens are slightly decreased along the die-filling direction due to the backflow of melt. Pure （Al ＋ Mg2Si） eutectic layer and ultra-fine-size α2-Al grains observed are around the overflow channels. Mass feeding is predominantly responsible for the superior mechanical properties of the round bars as compared to those of plate-like samples.

关键词： high-pressure die casting Aluminum alloy Microstructure segregations Mechanicalproperties die-filling behavior Numerical simulation

Design of Mg-Zn-Si-Ca casting magnesium alloy with high thermal conductivity

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Journal of Magnesium and Alloys 2020年第1期8卷 184-191页

作者： V.E.Bazhenov A.V.Koltygin M.C.Sung S.H.Park A.Yu.Titov V.A.Bautin S.V.Matveev M.V.Belov V.D.Belov K.V.Malyutin National University of Science and Technology“MISiS” Leninskiy pr.4Moscow 119049Russia LG Electronics Inc. Yeoui-daeroYeongdeungpo-gu.128LG Twin TowerSeoul 07336 Republic of Korea

Magnesium alloys are commonly used to produce lightweight *** most magnesium alloys exhibit low thermal conductivities,high thermal conductivities are needed for electronic *** this study,we attempted to develop new magnesium casting alloys with high thermal *** Mg-Zn-Si-Ca alloy compositions were chosen using CALPHAD(CALculation of PHAse Diagrams)calculations,and alloy samples were *** fluidity and hot-tearing resistance were *** results indicated that these properties were similar to those of AZ91 *** tests showed that high-pressure die casting could produce Mg-Zn-Si-Ca alloys possessing mechanical properties 1.5-3 times higher than those produced via sand *** alloy thermal conductivity was 126 W/mK at room *** corrosion rates of the as-cast samples in NaCl/water solutions were two times higher than that of AZ91.

关键词： Magnesium alloy Thermal conductivity Phase composition Corrosion rate Sand casting high-pressure die casting

Characterization on the formation of porosity and tensile properties prediction in die casting Mg alloys

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Journal of Magnesium and Alloys 2022年第7期10卷 1857-1867页

作者： Zixin Li Dejiang Li Wenke Zhou Bo Hu Xingfeng Zhao Jingya Wang Ming Qin Jiangkun Xu Xiaoqin Zeng National Engineering Research Center of Light Alloy Net Forming School of Materials Science and EngineeringShanghai Jiao Tong University800 Dongchuan RoadShanghai 200240China Hitachi(China)Research&Development Corporation Rui Jin BuildingNo.205 Maoming Road(S)Shanghai 200020China The State Key Laboratory of Metal Matrix Composites Shanghai Jiao Tong University800 Dongchuan RoadShanghai 200240China

The 3D visualization of the porosity in high-pressure die casting(HPDC)Mg alloys AZ91D and Mg4Ce2Al0.5Mn(EA42)was investigated by X-ray computed *** was demonstrated that the volumetric porosity at the near-gate location for alloy EA42 was significantly higher than that far from the gate *** difference resulted from the low valid time during intensified casting pressure *** of alloy EA42 exhibited a narrow pore distribution in the side view(~0.5 mm)compared to the wide distribution(~1.8 mm)of alloy AZ91D,which was mainly attributed to the formation mechanism of the defect *** formation of microporosity in the defect band of alloy EA42 was inhibited because of the significant latent heat released by a large amount of the Al11Ce3phase segregated in the defect band during ***,an effective estimator(Z-Propagation)was introduced,which is proposed to predict the projected area fraction of the porosity(f)involved during tensile failure with better effectiveness compared with traditional methods based on the actual fractured *** coupling the Z-Propagation method with the critical local strain model,the logarithmic fracture strain and true fracture stress of the specimens were predicted within 3.03%and 1.65%of the absolute value of the average relative error(AARE),respectively.

关键词： high-pressure die casting Porosity Tensile property Magnesium alloy X-ray computed tomography