Influence of Die Soldering on Die Erosion and Soldering Layer Between Al Melts and Die in Al-Si-Fe Alloys

The major problem in aluminum industry is a die soldering resulted from chemical and physical reactions of mold and molten aluminum in die casting process. The reactions lead to the formation of intermetallic compounds such as Al-Fe and Al-Fe-Si phases when the molten aluminum contains Si. The diffusion reaction causes die erosion and forms a soldering layer on the aluminum casting products leading to bad die accuracy and the quality of aluminum products. In this study, Fe and Si contents were varied simultaneously with reaction time. The thickness of the die erosion and die soldering layer is changed with composition of aluminum alloys and reaction time. The thickness of die erosion decreases when the aluminum alloy contains Fe. In case of the die soldering layer, the thickness decreases as increasing Si contents in aluminum alloy. Additionally, the layer is divided into two regions and they are identified as Fe2Al5 and FeAl3.