Effect of casting parameters on the microstructure and mechanical properties of squeeze cast A380 aluminum die cast alloy

A380 Al-Si-Cu die casting alloy is the most common of all die casting Al alloys and is used especially in the automotive industry due to the best combination of utility and cost. A high percentage of these components are produced by a high pressure die casting process; however, the quality and performance of these components need to be improved. Therefore, different approaches to component-making have been introduced such as semi-solid forming or squeeze casting over the last four decades. In the present study, direct squeeze casting of A380 alloy as a function of applied pressure was investigated. Applied pressures from 10 MPa to 50 MPa were considered and compared with gravity die cast samples. SDAS values ranging from 5.70 µm to 10 µm have been obtained by squeeze casting whereas 13.70 µm was found in gravity die casting. Density measurements and mechanical tests show us that the porosity level and presence of micro-voids were greatly decreased with increasing pressure while ultimate tensile strength and elongation increased in squeeze cast parts.