Experimental and numerical analysis of gas entrapment defects in plate ADC12 die castings

During die casting process, liquid melt injected fills die cavity with high velocity, which commonly results in entrapment of gas and induces final porosities. In this study, the plate ADC12 die castings were fabricated. The tensile specimens were obtained from the casting of different parts, and mechanical properties of the specimens were measured. The fractions and maximum size of porosities induced by gas entrainment were analyzed quantitatively. The effect of the fraction and size on the mechanical properties was analyzed and discussed, and the critical porosity fraction and size were proposed for ADC12 die castings. Furthermore, the gas entrapment of the plate die castings was simulated numerically. The simulation results were compared with the experimental analysis, and then discussed.