The effect of slow shot speed and casting pressure on the 3D microstructure of high pressure die casting AE44 magnesium alloy

3D reconstruction and 2D observation were conducted to characterize the microstructure of the castings produced through high pressure die casting with different parameters. Our results indicate that shrinkage pores generally co-existed with externally solidified crystals (ESCs). In specimen produced without fast slow shot speed, big net-shrinkage pores accompanied with ESCs were found in the center of the specimen. When the casting pressurization was introduced, the shrinkage pores gathered to the specimen center and became much less due to the optimization of melt feeding. Much more porosity was found near the gate rather than in the middle of the rod bar, especially gas pores. The filling process simulation reveals that the middle position of the bars was firstly filled and followed by the near gate position accompanied with one intense turbulent flow.