Residual stress analysis applied to HPDC aluminium components: a case study

High-Pressure Die Casting (HPDC) is a casting process largely diffused in the aluminium foundries. By HPDC is possible to obtain aluminium castings with thin walls and high specific mechanical properties in short cycle times. Aluminium HPDC castings are commonly intended for the automotive sector: engine, covers, engine blocks and more in general the powertrain. In recent years, one of the most important focus in the automotive sector is decreasing the powertrain weight, acting on stock allowances in certain parts of the casting. This reduction can affect the dimensional features and in turn the residual stress inside the casting. Despite that, it is possible to obtain beneficial compression states into the castings by mean of post-process operations, such as shot-blasting, to reduce or remove residual stresses by mean of heat treatments. Residual stresses can be assessed by an X-Ray residual stress measurement device, a nondestructive technique that allows observing the process parameters effect into the casting. In this work, after a detailed analysis of the residual stress measurement available for aluminium castings, a powertrain component realized in aluminium alloy EN AC 46000 was analysed. These analyses involved both dimensional response and related residual stresses in the as-cast state and the shot-blasted-state on a valve cover, to understand and prevent the residual stress states into the aluminium castings.