1、BSI Standards Publication PD CEN/TR 16749:2014 Aluminium and aluminium alloys Classification of Defects and Imperfections in High Pressure, Low Pressure and Gravity Die Cast ProductsPD CEN/TR 16749:2014 PUBLISHED DOCUMENT National foreword This Published Document is the UK implementation of CEN/TR 1
2、6749:2014. The UK participation in its preparation was entrusted to Technical Committee NFE/35, Light metals and their alloys. A list of organizations represented on this committee can be obtained on request to its secretary. This publication does not purport to include all the necessary provisions
3、of a contract. Users are responsible for its correct application. The British Standards Institution 2014. Published by BSI Standards Limited 2014 ISBN 978 0 580 86320 2 ICS 77.120.10 Compliance with a British Standard cannot confer immunity from legal obligations. This Published Document was publish
4、ed under the authority of the Standards Policy and Strategy Committee on 31 October 2014. Amendments/corrigenda issued since publication Date T e x t a f f e c t e dPD CEN/TR 16749:2014TECHNICAL REPORT RAPPORT TECHNIQUE TECHNISCHER BERICHT CEN/TR 16749 October 2014 ICS 77.120.10 English Version Alum
5、inium and aluminium alloys - Classification of Defects and Imperfections in High Pressure, Low Pressure and Gravity Die Cast Products Aluminium et alliages daluminium - Classification des dfauts et imperfections des produits mouls par coule haute pression, basse pression et gravit Aluminium und Alum
6、iniumlegierungen - Klassifikation von Fehlern und Unvollkommenheiten fr Druckguss, Niederdruckguss und Schwerkraftkokillenguss This Technical Report was approved by CEN on 9 September 2014. It has been drawn up by the Technical Committee CEN/TC 132. CEN members are the national standards bodies of A
7、ustria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sw
8、eden, Switzerland, Turkey and United Kingdom. EUROPEAN COMMITTEE FOR STANDARDIZATION COMIT EUROPEN DE NORMALISATION EUROPISCHES KOMITEE FR NORMUNG CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels 2014 CEN All rights of exploitation in any form and by any means reserved worldwide for
9、CEN national Members. Ref. No. CEN/TR 16749:2014 EPD CEN/TR 16749:2014 CEN/TR 16749:2014 (E) 2 Contents Page Foreword 5 1 Scope . 6 2 Normative references . 6 3 Terms and definitions . . 6 4 Classification of defects and imperfections in high pressure, low pressure and gravity die cast products . .
10、8 4.1 General 8 4.2 Classification . . 9 5 Definition of defects and imperfections . 10 5.1 General 10 5.2 Shrinkage defects and imperfections . . 11 5.3 Gas-related defects and imperfections . . 11 5.4 Filling-related defects and imperfections . . 12 5.5 Undesired phases . 12 5.6 Thermal contractio
11、n defects and imperfections . 12 5.7 Metal-die interaction defects and imperfections . 13 5.8 Geometrical defects and imperfections . 13 Annex A (informative) Description of defects and imperfections in High Pressure, Low Pressure and Gravity Die Cast Products . . 14 A.1 Internal defects and imperfe
12、ctions . 14 A.1.1 Shrinkage defects and imperfections . . 14 A.1.1.1 Macro-shrinkage (Type A1.1) . . 14 A.1.1.2 Interdendritic shrinkage (Type A1.2) . . 14 A.1.1.3 Layer porosity (Type A1.3) . . 15 A.1.2 Gas-related defects and imperfections . . 16 A.1.2.1 Air entrapment porosity (Type A2.1) . . 16
13、A.1.2.2 Hydrogen porosity (Type A2.2) . 17 A.1.2.3 Vapor entrapment porosity (Type A2.3) . 18 PD CEN/TR 16749:2014 CEN/TR 16749:2014 (E) 3 A.1.2.4 Lubricant/release agent entrapment porosity (Type A2.4). 18 A.1.3 Filling-related defects and imperfections . . 19 A.1.3.1 Cold joint (Type A3.1). 19 A.1
14、.3.2 Lamination (Type A3.2) . . 20 A.1.3.3 Cold shot (Type A3.3). 20 A.1.4 Undesired phases . 21 A.1.4.1 Inclusion (Type A4.1) . 21 A.1.4.2 Undesired structure (Type A4.2) . 21 A.1.5 Thermal contraction defects and imperfections . 22 A.1.5.1 Cold crack (Type A5.1) . 22 A.1.5.2 Hot tear, hot crack (T
15、ype A5.2) . 23 A.2 Surface defects and imperfections . 24 A.2.1 Shrinkage defects and imperfections . . 24 A.2.1.1 Sink (Type B1.1) 24 A.2.2 Gas-related defects and imperfections . . 25 A.2.2.1 Blister (Type B2.1) . . 25 A.2.2.2 Pinhole (Type B2.2) . . 25 A.2.3 Filling-related defects and imperfecti
16、ons . . 26 A.2.3.1 Cold joint and vortex (Type B3.1) . 26 A.2.3.2 Lamination (Type B3.2) . . 27 A.2.3.3 Cold shot (Type B3.3). 27 A.2.4 Undesired phases . 28 A.2.4.1 Surface deposit (Type B4.1) . . 28 A.2.4.2 Contaminant or inclusion (Type B4.2) . . 28 A.2.5 Thermal contraction defects and imperfect
17、ions . 29 A.2.5.1 Cold crack (Type B5.1) . 29 A.2.5.2 Hot tear, hot crack (Type B5.2) . 30 A.2.6 Metal/die interaction defects and imperfections . 30 A.2.6.1 Erosion (Type B6.1) . . 30 A.2.6.2 Soldering (Type B6.2). 31 PD CEN/TR 16749:2014 CEN/TR 16749:2014 (E) 4 A.2.6.3 Thermal fatigue marks (Type
18、B6.3) . 31 A.2.6.4 Ejection mark (Type B6.4) . 32 A.2.6.5 Corrosion of the die (Type B6.5) . 32 A.3 Geometry defects and imperfections . 33 A.3.1 Lack of material - Incompleteness (Type C1.1) . 33 A.3.2 Excess of material - Flash (Type C2.1) . 33 A.3.3 Out of tolerance - Deformation (Type C3.1) . 34
19、 Annex B (informative) Translations of defects and imperfections terminology . . 35 Annex C (informative) Examples of detection techniques and size of defects and imperfections . 37 Bibliography . 39 PD CEN/TR 16749:2014 Foreword This document (CEN/TR 16749:2014) has been prepared by Technical Commi
20、ttee CEN/TC 132 “Aluminium and aluminium alloys”, the secretariat of which is held by AFNOR. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CEN and/or CENELEC shall not be held responsible for identifying any or all such patent r
21、ights. CEN/TR 16749:2014 (E)PD CEN/TR 16749:2014 1 Scope This Technical Report specifies the classification of the defects and imperfections may be present in cast products manufactured by high pressure, low pressure and gravity die casting of aluminium alloys. 2 Normative references The following d
22、ocuments, in whole or in part, are normatively referenced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 12258-1:2012, Alumi
23、nium and aluminium alloys - Terms and definitions - Part 1: General terms 3 Terms and definitions For the purposes of this document, the terms and definitions given in EN 12258-1:2012 and the following apply. 3.1 casting process process in which molten metal is introduced into a mould where it solid
24、ifies SOURCE: EN 12258-1:2012, 3.1.1 3.2 die casting process casting process in which molten metal is injected under substantial pressure, typically above 70 bars, into a metal die and solidifies under this pressure Note 1 to entry: Die casting process is also referred to as “pressure die casting (p
25、rocess)” or “high pressure die casting (process)”. SOURCE: EN 12258-1:2012, 3.1.10 3.3 permanent mould casting process casting process in which molten metal is introduced by gravity or low pressure into a mould constructed of durable material, typically iron or steel Note 1 to entry: A permanent mou
26、ld casting process where the metal solidifies in a metal mould under low pressure (typically less than 1 bar above atmospheric pressure) is also referred to as a “low pressure die casting process”. SOURCE: EN 12258-1:2012, 3.1.9 3.4 casting product at or near finished shape, formed by solidification
27、 of the metal in a mould or a die SOURCE: EN 12258-1:2012, 2.5.1 3.5 dendrite crystal that has a tree-like, branching pattern, being most evident in cast metals slowly cooled through the solidification range SOURCE: EN 12258-1:2012, 4.5.17 CEN/TR 16749:2014 (E)PD CEN/TR 16749:2014 3.6 microstructure
28、 structure of a metal as revealed by microscopic examination of a surface, typically after mechanical and/or chemical preparation, e.g. polishing and micro-etching SOURCE: EN 12258-1:2012, 4.5.10 3.7 dendrite arm spacing mean distance of adjacent secondary arms of a dendrite SOURCE: EN 12258-1:2012,
29、 4.5.18 3.8 defect quality characteristic which is lower with respect to the level or state foreseen (usually specified) and which does not allow the product to carry out a function requested SOURCE: EN 12258-1:2012, 7.1.2 3.9 imperfection quality characteristic which is for a some extent lower with
30、 respect to the level or state foreseen or a deviation from a continuous appearance of the base material not yet evaluated against a threshold level (a technical OK / not OK evaluation is not allowed) Note 1 to entry: The term “inhomogeneity” can also be used. Note 2 to entry: This does not mean nec
31、essarily that the product is not suitable for use. An imperfection needs to be evaluated by means of a proper scale, based on the related specifications, to decide if the product has a quality level making it suitable for the use. 3.10 shrinkage cavity void left in cast metals as a result of solidif
32、ication shrinkage SOURCE: EN 12258-1:2012, 5.2.10 3.11 gas porosity porosity caused by entrapped gas, evolution by evaporated organic release compounds, or by evolution of dissolved hydrogen during solidification 3.12 inclusion extraneous material accidentally entrapped into the liquid metal and who
33、se possible root causes are melt treatment procedures initiating oxidation, transported to the melt by contaminated ingot surfaces, transported into castings due to abrasion of process equipment, entrapped into the metal surface during hot or cold working 3.13 blister raised spot whose inside is hol
34、low, that forms on the surface of products and is caused by the expansion of entrapped gas at the opening of the die or during conditions of elevated temperature in subsurface regions, typically during thermal treatment CEN/TR 16749:2014 (E)PD CEN/TR 16749:2014 3.14 hot crack crack formed in a cast
35、metal or in a welding because of internal stress developed upon cooling at the solidus temperature or slightly above SOURCE: EN 12258-1:2012, 5.2.8 3.15 cold crack crack in cast metal initiated by mechanical stresses at temperatures significantly below the solidus temperature SOURCE: EN 12258-1:2012
36、, 5.2.9 3.16 corrosion deterioration of a metal by chemical or electrochemical reaction with its environment SOURCE: EN 12258-1:2012, 5.6.14 3.17 flash thin protrusion into the parting surface of a die which forms when metal, in excess of that required to fill the impressions, is forced between the
37、die interfaces 4 Classification of defects and imperfections in high pressure, low pressure and gravity die cast products 4.1 General Defects and imperfections implemented in the present classification are metallurgy-related, i.e. directly bound to high pressure, low pressure and gravity die casting
38、 processes. The defects and imperfections are classified using a scheme based on three levels: a) The level I is based on morphology/location of defects and imperfections, with reference to the investigation techniques suitable for their detection (visual inspections and controls involving the bulk
39、material): there are internal (Table 1) and external or surface (Table 2) defects and imperfections. Sub- surface defects and imperfections (i.e. so close to the surface that they can affect external aspect detectable by conventional surface investigation techniques) are considered surface defects a
40、nd imperfections. Finally, the geometrical defects and imperfections (Table 3) refer to the casting shape in terms of dimensions and tolerances. b) The level II is mainly focused on the metallurgical, physical, chemical and process-based origin of defects and imperfections. They are grouped into sev
41、eral classes according to their general metallurgical origin: 1) defects and imperfections related to the presence of gas (gas-related defects and imperfections); 2) defects and imperfections related to material volume contraction during metal solidification (shrinkage defects and imperfections); 3)
42、 defects and imperfections related to thermal contraction prevented by previously solidified metal or by the die (thermal contraction defects and imperfections); 4) defects and imperfections related to incorrect filling of the die-cavity (filling defects and imperfections); CEN/TR 16749:2014 (E)PD C
43、EN/TR 16749:2014 5) defects and imperfections related to metal/die interaction; 6) defects and imperfections related to the presence of unsuitable phases (undesired phases), originating from the interaction of the metal with external environment during melting, pouring, casting, filling or extractio
44、n/ejection from the die. As previously observed, the knowledge of metallurgical origin could supply starting points for corrective actions (e.g. on process parameters). c) The level III is used to identify the specific types of defects and imperfections. Usually, the term adopted to describe a parti
45、cular type of defect and imperfection allows a better definition of its metallurgical origin, which was preliminarily identified in the previous level. NOTE Other defects and imperfections, related to subsequent operations (handling finishing, machining), have not been considered. 4.2 Classification
46、 Table 1 Classification of internal defects and imperfections Level I Level II Level III A Internal defects and imperfections A1 Shrinkage defects and imperfections A1.1 Macro-shrinkage A1.2 Interdendritic shrinkage A1.3 Layer porosity A2 Gas-related defects and imperfections A2.1 Air entrapment por
47、osity A2.2 Hydrogen porosity A2.3 Vapour entrapment porosity A2.4 Lubricant and/or die release agent entrapment porosity A3 Filling-related defects and imperfections A3.1 Cold joint A3.2 Lamination A3.3 Cold shot A4 Undesired phases A4.1 Inclusion A4.2 Undesired structure A5 Thermal contraction defe
48、cts and imperfections A5.1 Cold crack A5.2 Hot tear, hot crack CEN/TR 16749:2014 (E)PD CEN/TR 16749:2014 Table 2 Classification of surface defects and imperfections Level I Level II Level III B Surface defects and imperfections B1 Shrinkage defects and imperfections B1.1 Sink B2 Gas-related defects
49、and imperfections B2.1 Blister B2.2 Pinhole B3 Filling-related defects and imperfections B3.1 Cold joint, Vortex B3.2 Lamination B3.3 Cold shot B4 Undesired phases B4.1 Surface deposit B4.2 Contamination, inclusion B5 Thermal contraction defects and imperfections B5.1 Cold crack B5.2 Hot tear, hot crack B6 Metal-die interaction defects and imperfections B6.1 Erosion B6.2 Soldering B6.3 Thermal fatigue marks B6.4 Ejection mark B6.5 Corrosion of the die Table 3 Classification of geometrical defects and imperfections Level I Level II Level III C G
