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The demands on ductility and fatigue strength of structural and chassis components are significantly higher than with other parts produced using cold-chamber-die-casting. Whereas, macroscopic oxide inclusions can be detected, classified as undesirable and removed from the production process by simple methods, the dispersed, ultrafine oxides which are more hidden are the so far underestimated source of extensive damage with regard to the ductility and fatigue strength of components produced in high-pressure-die-casting. Assuming that future applications of die-cast-components will increase demands even further, the author proposes an ultimate approach to solving these inherent problems by transferring experience from proven systems in the field of low-pressure-die-casting towards high-pressure-die-casting. In the currently dominating derivatives of the high-pressure die-casting method used for aluminium and its alloys, a great deal of effort is made to compensate for the symptoms of the more or less inherent disadvantages of very fast filling of the mould cavity. Basically, however, it must be assumed that most of the dispersed oxide-films are formed already at the stage of filling the aluminium into the shot-sleeve. This has led to a search for solutions in which the shot-sleeve is filled from below independent of evacuation of the mould cavity. As a result, various comparative studies have shown that components made by filling the mould cavity from below, combined with stronger evacuation of the cavity, produced the lowest amount of fine porosity in heat-treated parts. The author is convinced that the proposed concept of bottom-filling the slot sleeve under inert-gas-protection is ideally suited to producing high standard components of exceptional metallurgical quality. Combined with proven vacuum technology, die tempering and water-free spraying methods, it should ultimately be possible to achieve exceptionally high component properties.

Contribution to Solving an Inherent Problem When High Pressure Die-Casting Aluminium and its Alloys