The Effect of Process Parameters on the Properties and Microstructure of A380 Aluminum Alloy Casting with Different Wall Thicknesses

In the present work, the effects of different die-casting process parameters on the mechanical properties and microstructure of A380 aluminum alloy casting with different wall thicknesses during the solidification process have been experimentally investigated. The experimental results show that both boost pressure and injection speed have a significant effect on the mechanical properties of the casting. As the injection speed increases, the changes in mechanical properties are more significant in the thin-walled area, while increasing the boosting pressure has a greater effect on the mechanical properties of the thick-walled area. In addition, the evolution of microstructure composition, including the α-Al phase, eutectic Si phase and Al-Si-Fe-Mn phase, has been analyzed and compared by energy-dispersive spectroscopy (EDS), optical microscopy (OM) and scanning electron microscopy (SEM). It was found that the α-Al phase in the thin-walled area is significantly refined with the increase of injection speed. Meanwhile, with the increase of boost pressure, the α-Al phase in the thick-walled area gradually becomes finer, and the distribution of the eutectic Si phase and the Al-Si-Fe-Mn phase in the alloy becomes more uniform. Thus, the injection speed and boost pressure have an important impact on the overall forming quality of the casting.