MICROSTRUCTURE SIMULATION OF HIGH PRESSURE DIE CAST MAGNESIUM ALLOY BASED ON MODIFIED CA METHOD

doi:10.3724/SP.J.1037.2010.00279

Acta Metall Sin

2010, Vol. 46

Issue (12): 1534-1542 DOI: 10.3724/SP.J.1037.2010.00279

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MICROSTRUCTURE SIMULATION OF HIGH PRESSURE DIE CAST MAGNESIUM ALLOY BASED ON MODIFIED CA METHOD

WU Mengwu, XIONG Shoumei

State Key Laboratory of Automobile Safety and Energy, Department of Mechanical Engineering, Tsinghua University, Beijing 100084

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WU Mengwu XIONG Shoumei. MICROSTRUCTURE SIMULATION OF HIGH PRESSURE DIE CAST MAGNESIUM ALLOY BASED ON MODIFIED CA METHOD. Acta Metall Sin, 2010, 46(12): 1534-1542.

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Abstract As the lightest structural material, magnesium alloy has been widely used in the automotive, aerospace and electronic industries. High pressure die casting (HPDC) process is the dominant process for magnesium alloy products. The microstructure of die cast magnesium alloy has a great influence on the final performance of the castings. Numerical simulation provides a way to predict the solidification structure and the corresponding mechanical properties. However, as one of the most widely used methods in microstructure simulation, the cellular automaton (CA) method has difficulties in simulating the solidification structure of magnesium alloy with hcp crystal structure, though simulations of solidification structure for bcc and fcc metals have been widely reported. Besides, for the microstructure simulation of magnesium alloys by HPDC process, accurate nucleation model has to be considered, and by far little report was found on it. In the present paper, based on the accurate temperature field of die castings obtained by an inverse heat transfer model, analysis of the temperature curves during solidification was made to establish a nucleation model that correlated the cooling rate with the nucleation density of magnesium alloys during solidification of HPDC process. A modified CA model was also developed to simulate the crystal growth of magnesium alloys. It takes account of the solute diffusion, constitutional undercooling, curvature undercooling, and anisotropy etc. Validations were made to the model, and the results show that the model has the capability to simulate the dendrite growth of magnesium alloy with different growth orientations. Besides, the model can also reveal the dendrite morphology with features of secondary and ternary dendrite branches, the dendrite competition growth under different temperature gradients and solidification rates, and the three dimensional morphology of the dendrite growth. To validate the nucleation and growth model established for magnesium alloy under HPDC process, "step–shape" die castings of AM50 magnesium alloy were produced at different process parameters. The average grain size prediction results are in good agreement with the experimental ones.

Key words: magnesium alloy high pressure die casting dendrite growth nucleation model microstructure simulation

Received: 10 June 2010

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Supported by National Science and Technology Major Project of the Ministry of Science and Technology of China (No.2009ZX04014–082), National High Technology Research and Development Program of China (No.2009AA03Z114) and Toyo Machinery & Metal Co., Ltd. (No.083000148)

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https://www.ams.org.cn/EN/10.3724/SP.J.1037.2010.00279 OR https://www.ams.org.cn/EN/Y2010/V46/I12/1534

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