A recent article in Die Casting Engineer magazine (Sept 2004 p40) discusses the problem facing magnesium die casters relating to cavity fill.  In the article, solidification analysis is discussed along with its relationship to trapped gases that affect porosity levels.  These trapped gases negatively affect the casting quality and integrity.

Although magnesium is being used more and more, many aluminum parts are still being produced especially for automotive components.

As a member of the general die casting community, we want to make you aware of two benefits that

 MetaLL ifeÒ provides that relate directly to this problem in both magnesium and aluminum castings.

The MetaLL ifeÒ resultant topography change provides a mechanism that enhances metal flow and at the same time helps break up the trapped gases in the molten  metals thereby reducing porosity concentrations.

Magnesium castings, in most instances, are thinner than aluminum.  Magnesium pour temperature is also lower than aluminum, which is a benefit in reducing thermal cracking.

As the metal flows into a die, the  molten metal solidifies with residual trapped gases causing porosity problems for die casters..

After a MetaLLifeÒ application, however, the molten metal flow is equalized, and interrupted so that any trapped gases that are present  are broken down by the micro topography peaks into smaller and more homogeneous levels.

Many in the die casting community have been using this benefit to their advantage for years.

We had thought that this was common knowledge to the general die casting industry. 

From the article, however, we see that many still struggle at times with porosity problem.  That is the reasoning behind our doing a follow-up to the Die Casting Engineer magazine article.

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