Formation of the surface layer in hypoeutectic Al-alloy high-pressure die castings

A layer of distinctive microstructure known as the surface layer or the skin is often observed near the casting surface of high-pressure die cast (HPDC) parts. With its different microstructure, the surface layer could influence mechanical performance, corrosion properties and also pressure tightness of the whole cast component. This research aims to develop a better understanding of surface layer formation, which is essential to control the microstructure and therefore properties of HPDC components. In this study, microstructural characterization has been performed on HPDC specimens cast from an HPDC-specific Al alloy for structural applications, AlMg5Si2Mn. Most regions in the samples investigated contain ∼10-30 μm globular-rosette primary α-Al grains and [Al + MgSi] eutectic, while very dendritic primary α-Al grains are also present in the surface layer. The surface layer was observed in the region where the alloy did not directly impinge on the die surface during die filling (the so-called indirect impingement zone). In the region between the surface layer and inner regions (the so-called surface-layer edge), the only primary grain population is the very dendritic grains also observed in the surface layer. The surface layer formation is related to shearing at the interface between two parts of material containing different solid fractions (f) which can occur either during the die-filling or during the intensification stage