CFD Analysis of Mechanisms Underlying the Porosity-reducing Effect of Atomized Flows in High-pressure Die Cast Products

In high-pressure die casting, attention has been paid to the J factor, which is defined by the speed of the metal injected at the gate and the shape of the gate. In casting experiments using a piston die, the porosity of the product can be reduced by increasing the J factor such that the metal flow passing through the gate forms an atomized flow. To clarify the underlying mechanisms, we developed a system for simulating a two-phase flow of air and aluminum by large-scale calculations of turbulent flow. During the development of the system, we injected metal into an open space and performed imaging to confirm the state of the atomized flow. The system was then verified by reproducing the atomized flow. The analysis results visualized the many small turbulent vortices generated in the thick part far from the gate. We demonstrated that the change from small to longitudinal vortices promoted entrainment of air into the aluminum and increased the efficiency of air expulsion outside the die through an increase in the J factor.