Investigation of gas porosity formation due to runner design by casting simulation in pressure die casting of aluminum alloys

High pressure die casting offers reduced costs due to its small tolerances, and smooth surface finish. Casting parts produced are consumed by the automotive industry in millions. In this study, the use of computer aided engineering applications on design of high pressure die casting dies was studied. The influence of casting process steps in the die design was studied and analysed. The cast materials used is 150 ETIAL alloy. The effects of runner design, gas porosity formation and die design parameters on casting product were studied. Finally the result of the simulation was used to improve and to solve problems of already in use die. The result show good correlation between simulation and experimentally obtained data.