POROSITY, DEFECT CONNECTIVITY AND TIGHTNESS IN Al-Si-Cu alloys PRODUCED BY HPDC: FOCUSED SYSTEMATIC REVIEW AND LEAKAGE RISK FRAMEWORK
DOI:
https://doi.org/10.66104/753t0462Keywords:
HPDC. Porosity. Tightness. Al-Si-Cu alloys. Risk of leakage.Abstract
High Pressure Die Casting (HPDC) of Al-Si-Cu alloys is widely used in the production of critical industrial components that require high tightness. However, the formation of porosity resulting from the entrapment of gases and contraction during solidification compromises the functional reliability of these parts. This focused systematic review integrates porosity formation mechanisms, process parameters, and their impacts on tightness performance, based on a structured search in the Web of Science, which resulted in a final portfolio of 12 articles selected by explicit eligibility criteria and comparative analysis. The results demonstrate that the volumetric fraction of porosity, alone, is not sufficient to predict functional failures, with connectivity, percolation, nature of defects and proximity to the surface being the most relevant factors for the risk of leakage. The most used characterization methods - metallography, X-ray radiography and micro-computed tomography (micro-CT) - and the main functional tests, with emphasis on the helium leak test and air decay test, are also critically discussed. Finally, a conceptual framework of industrial applicability is proposed that integrates process parameters, morphology and connectivity of defects, detection methods and functional validation of tightness, contributing to technical decision making in HPDC components subjected to severe sealing requirements.
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