Robust gate system design for precision semi-solid casting processes

Abstract

"Semi-solid casting (SSC) of magnesium alloys is increasingly being used to produce high quality components. Using this process, higher strength, thinner wall section and tighter tolerance without porosity are obtained. High-precision fabrication of thin-walled components with large surface area is possible. They are widely used for the IT, auto and consumer electronics industries. However, warpage degrade quality of the part produced in the SCC process. To produce thin-walled Mg alloy parts, the geometry of gating system affecting quality of the product should be thoroughly studied. In this paper, to minimize warpage of the thin-walled sections, Taguchi method is applied to the optimal design of the gate geometry in the thixomolding process. Width, height, length and angle of the gating system are selected for the robust design parameters. Effectiveness of the robust design is verified through the CAE software.