Mechanism of Lubrication-Induced Surface Cracking in Hot Chamber Die Cast Thin-Walled AZ91D Parts

Abstract

Thin-walled hot chamber die cast parts are often used to make telephone casings and similar products having primarily requirements on weight and aesthetically satisfying surfaces. The post casting surface treatment often generates a glossy appearance. The glossy appearance makes it extremely sensitive to small-scale flaws, such as blisters, cold shuts, and cracks. Hot chamber die casting of thin-walled parts requires high filling speed and the use of lubrication because the parts have high aspect ratios. In the manufacturing of such high aspect ratio parts with a wall thickness of 0.6 mm, a new type of cold crack induced by the lubrication is observed. To some extent this defect is similar to a blister, but the characteristic bump is not formed and the actual crack is formed by thermal contraction along the high aspect ratio areas.

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