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Optimization of process parameters is critical to minimize the porosity, as well as to maximize the strain at fracture performance of die cast components. In this paper, a two step design of experiments, derived from the Taguchi method, was used to determine the optimum parameter settings for AM60B magnesium die casting alloy. From result analysis, metal temperature and intermediate shot velocity are the most influential parameters for porosity, whereas cavity fill time is the most influential parameter for strain at fracture. Finally, unlike strain at fracture models which are not reproducible, the porosity models are reproducible for both stages of the experiments.

The conversion of a structural or non structural component to a different material such as magnesium, involves proper knowledge of the operating conditions, material properties, as well as the manufacturing processes. The present paper addresses some design aspects related to components produced using the high pressure die casting process. Simply converting from an aluminum die casting alloy to a magnesium alloy using an existing tool may appear very attractive to designers in the first place due to the apparent cost savings and short transition time involved. Although one can not generalize that this procedure is common practice, it is being employed. However, the final product may not represent an optimized design considering weight reduction and structural performance requirements. When directly converting a component to a new material, some design specifications and operating conditions may inadvertently be overlooked.