Prediction of Zinc Deposition on Mold Surfaces in Zinc Alloy Die Casting Using a New Simulation-Based Evaluation Method

Sakuragi T, Fuwa D, Nakayama I and Tomioka Y

Published on: 2024-10-31

Abstract

In the die casting process, the adhesion of the zinc alloy to the mold surface, which occurs over an extended period, hinders continuous production. The adhesion of the metal alloy to the mold surface is believed to occur not only due to the soldering reaction between the zinc alloy and the mold surface but also due to lamination caused by rapid solidification.

In this study, our goal is to predict the areas of zinc alloy adhesion on the mold surface that result from lamination after prolonged die casting. We derived the cooling rate at which lamination occurs. Additionally, it has been confirmed from actual die casting experimental data that this lamination causes zinc alloy adhesion on the movable mold surface [3].

We propose a new evaluation method based on the cooling rate predicted from mold filling simulation and heat transfer analysis inside the mold to predict the areas where lamination will occur on the mold surface. The predicted results using the proposed method showed a very good agreement with the areas where zinc deposition was observed in the experiments.