Failure Investigation of an AlSi9Cu3 Alloy Die-Cast Cavity Insert
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The examination of a fractured cavity insert, cooperated die to finish geometry intricate aluminum alloy die-casting product, is described. The dominating failure mechanism in the investigated insert is the combination of thermal fatigue cracking and stress concentration. A visual fractographic examination was performed at the cavity insert and crack initiated at the periphery adjacent to a sharp corner. Detailed scanning electron microscopy observations and energy-dispersive X-ray suggest that the crack growth was facilitated by a number of elements: oxidation of the cracks’ surfaces, filling of cast alloy, and high stress concentration of the sharp corner. The thermal cracks were also produced product around the inside wall of the cooling channel. Similarly, these cracks were also subjected to oxidation and filling with scale deposit and oxide. Finally, the schematic of the cavity insert fracture evolution during die-casting is discussed.
KeywordsDie-casting Cavity insert Thermal fatigue crack Stress concentration Fracture
The authors gratefully acknowledge the National Natural Science Foundation of China (Grant No. 51374151), the Natural Science Foundation of Shanxi Province (Grant Nos. 2015011038, 201701D121041), and the Ph.D. Scientific Research Startup Foundation (Grant No. 20152011) of TYUST for funding provided in support of this work.
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