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Metals 2016, 6(1), 24; doi:10.3390/met6010024

Aluminium Foam and Magnesium Compound Casting Produced by High-Pressure Die Casting

1
Department of Foundry and Steel making, Tecnalia Research & Innovation, c/Geldo, Edif. 700, E-48160 Derio, Spain
2
Department of Aerospace, Tecnalia Research & Innovation, c/Mikeletegi 2, E-20009 Donostia, Spain
3
Industrias Lebario, c/Arbizolea 4, E-48213 Izurza, Spain
These authors contributed equally to this work.
This author supervised this work.
*
Author to whom correspondence should be addressed.
Academic Editor: Hugo F. Lopez
Received: 9 November 2015 / Revised: 23 December 2015 / Accepted: 11 January 2016 / Published: 15 January 2016
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Abstract

Nowadays, fuel consumption and carbon dioxide emissions are two of the main focal points in vehicle design, promoting the reduction in the weight of vehicles by using lighter materials. The aim of the work is to evaluate the influence of different aluminium foams and injection parameters in order to obtain compound castings with a compromise between the obtained properties and weight by high-pressure die cast (HPDC) using aluminium foams as cores into a magnesium cast part. To evaluate the influence of the different aluminium foams and injection parameters on the final casting products quality, the type and density of the aluminium foam, metal temperature, plunger speed, and multiplication pressure have been varied within a range of suitable values. The obtained compound HPDC castings have been studied by performing visual and RX inspections, obtaining sound composite castings with aluminium foam cores. The presence of an external continuous layer on the foam surface and the correct placement of the foam to support injection conditions permit obtaining good quality parts. A HPDC processed magnesium-aluminium foam composite has been developed for a bicycle application obtaining a suitable combination of mechanical properties and, especially, a reduced weight in the demonstration part. View Full-Text
Keywords: high pressure die casting (HPDC); hybrid magnesium aluminium foam cast composite; aluminium foam core; magnesium cast composite high pressure die casting (HPDC); hybrid magnesium aluminium foam cast composite; aluminium foam core; magnesium cast composite
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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MDPI and ACS Style

Vicario, I.; Crespo, I.; Plaza, L.M.; Caballero, P.; Idoiaga, I.K. Aluminium Foam and Magnesium Compound Casting Produced by High-Pressure Die Casting. Metals 2016, 6, 24.

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