Fluidity, Microstructural Characteristics, and Analytical Models of High-Pressure Die-Cast Aluminum Alloys

doi:10.11900/0412.1961.2025.00266

Acta Metall Sin

2026, Vol. 62

Issue (5): 941-958 DOI: 10.11900/0412.1961.2025.00266

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Fluidity, Microstructural Characteristics, and Analytical Models of High-Pressure Die-Cast Aluminum Alloys

XIONG Shoumei¹^,²(

), HE Zunian¹(

)

1 School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China
2 Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, Tsinghua University, Beijing 100084, China

Cite this article:

XIONG Shoumei, HE Zunian. Fluidity, Microstructural Characteristics, and Analytical Models of High-Pressure Die-Cast Aluminum Alloys. Acta Metall Sin, 2026, 62(5): 941-958.

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Abstract

High-pressure die casting (HPDC), characterized by high filling speeds and rapid solidification, has become a key manufacturing process for large integrated aluminum alloy structural components in electric vehicles. However, in large thin-walled castings, complex coupling exists between melt flow behavior and the evolution of microstructural defects, and the underlying mechanisms remain insufficiently understood. This paper systematically reviews recent progress in the fluidity of aluminum alloys under HPDC conditions and establishes a unified analytical framework from three perspectives: process parameters, microstructural characteristics, and analytical models. First, the factors influencing fluidity in die casting are summarized, highlighting that both processing parameters and alloy design jointly affect fluidity by regulating heat transfer and solidification processes. Second, the formation mechanisms of the characteristic layered microstructure in die castings, including the skin layer, defect band, and externally solidified crystals (ESCs), are elucidated. The critical roles of dendritic network connectivity, solute enrichment, and pore evolution in flow stoppage are also discussed. Finally, the differences among various analytical models for fluidity are compared in terms of their physical assumptions and predictive capabilities. Overall, the fluidity of die cast alloys is governed by the coupled interactions of thermal, phase transformation, and flow fields. Future research should further focus on the mechanisms of flow stoppage, in situ synchrotron characterization, and data-driven approaches.

Key words: high-pressure die casting aluminum alloy fluidity

Received: 09 September 2025

ZTFLH:

TG24

Fund: National Key Research and Development Program of China(2022YFB3404201)

Corresponding Authors: HE Zunian, Tel: (010)62789448, E-mail: hezn23@mails.tsinghua.edu.cn; XIONG Shoumei, professor, Tel: (010)62773793, E-mail: smxiong@tsinghua.edu.cn

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https://www.ams.org.cn/EN/10.11900/0412.1961.2025.00266 OR https://www.ams.org.cn/EN/Y2026/V62/I5/941

Fig.1 Schematic of the mold for fluidity tests^[32] (a1), engineering drawing of the effective flow length^[32] (a2), fluidity samples under die-casting conditions showing effective flow length (b1)^[32] and defect flow end (b2), and OM images of pores at the defect flow end (c1) and ahead of the defect flow end (c2)

Fig.2 Fluidity test results of aluminum alloys under different process conditions with applied intensification pressure of 87 MPa
(a) total flow length under different gating speeds^[32]
(b) total flow length under different gating speeds in AlSi9MnVZr alloy^[32]
(c) effective flow length under different mold temperatures
(d) effective flow length under different superheats

Fig.3 Photos (a) and flow lengths in different Si contents (mass fraction) (b) of fluidity test of spiral die-cast parts^[37]

Fig.4 Fluidities of aluminum alloys under different Si contents and process parameters^[39]
(a) different Si contents and fast shot speeds (b) different Si contents and wall thicknesses

Fig.5 Microstructures of AlSi10MnMg alloy under different melt temperatures and slow shot speeds^[16] (a, c) 640 ^oC, 0.1 m/s (Green circle represents the defect band) (b, d) 680 ^oC, 0.2 m/s (e-g) magnified views of positions 4-6 in Fig.5c, respectively (h-j) magnified views of positions 7-9 in Fig.5d, respectively

Fig.6 Microstructures of cross sections of die-cast AlSi9MnVZr alloy under intensification pressures (I.P) of 0 MPa (a-e) and 13.7 MPa (f-j) with different wall thicknesses^[62] (a, f) 5 mm (b, g) 4 mm (c, h) 3 mm (d, i) 2 mm (e, j) 1 mm

Fig.7 3D reconstructions and microscopic characterization of pores at the fracture surface in AlSi10MnMg alloy^[65] (a-h) 3D reconstructions of the fracture surface and subsurface pores (i) SEM images of the fracture surface

Fig.8 Microstructures of A356 alloy castings produced by simulating the high pressure die casting process through alloy pretreatment and modified gravity casting mold^[54]
(a) f_s^ESC = 0.16, T_die = 270 ^oC (f_s^ESC—volume fraction of ESCs, T_die—die temperature)
(b) f_s^ESC = 0.11, T_die = 270 ^oC

Fig.9 Schematic of defect band formation induced by high shear strain and compression regions^[67]

Fig.10 Schematic of the solid fraction gradient from the mold wall to the channel center, where darker shades represent higher solid fractions (f_s). The diagram also shows the variation of stress response along the solid fraction gradient. Line A denotes the lower bound of the applied stress within the viscoelastic regime, and line B represents the iso-line where the deformation rate exceeds the interdendritic flow rate

Fig.11 Schematic of one-dimensional basic model (x direction—flow direction, d—wall thickness, w—channel width, v—flow speed, T(x)—melt temperature that varies with x)

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