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In recent years, studies have been conducted on the relationship between the J factor, which indicates flow of molten aluminum at the time of injection, and the quality of HPDC products. The flow of molten metal at a high J factor is referred to as “Atomized Flow.” The authors and others conducted studies on the relationship between the J factor and the strength of HPDC products. An area exceeding 300MPa was found in the product produced at a high J factor corresponding to the “Atomized Flow.” The defect was less in the above-mentioned position because the gas porosity was finely dispersed. Considering that the fine dispersion of gas porosity is related to the “Atomized Flow”, pictures were taken to analyze “Atomized Flow.” The molten aluminum was ejected into an open space at a high speed and the splashed conditions were photographed. From the images taken by the pulse laser permeation, the conditions of microscopic atomized flow were observed precisely.

With the growing demand of weight reduction in recent years, hollow structural casting products, which are weldable, of high strength and rigidity, are produced by high-pressure die-casting. In order to develop such a cast product in a short period of time, techniques are required to predict the castability, weldability, strength, quality at an early stage of development. The conventional simulations, however, are unable to satisfy the aforementioned demands. In an attempt to respond to those demands, the authors through this reported research quantifiably analyzed the porosity in the casting, and realized predicting of actual strength and elongation. By applying the newly developed casting simulation to the motorcycle parts, the cast part design can be accurately verified, allowing signification reduction of the thickness and weight.