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The long-term objective of this work is to develop design and modeling tools that allow the structural behavior of thin-walled cast components to be predicted when subjected to static and dynamic loads such as in crash situations. Here, the energy absorption potential of High Pressure Die Cast components made of magnesium alloys AM20, AM50, AM60, AZ91 and the aluminum alloy AlSi7Mg is investigated using a shear-bolt principle. For the AM60 alloy, single plates cast with different thickness have been tested in order to investigate the effect of plate thickness on the shear-bolt mechanism. It is found that this deformation principle gives an approximately constant mean force during the deformation process. The behavior seems to be very robust, especially for the magnesium alloys. A simple empirical model for prediction of the mean shearing force as a function of plate thickness and bolt diameter is proposed.

A methodology that includes the processing history of the metal in the High Pressure Die Casting (HPDC) process in the simulations of the structural behavior of magnesium components has been established. In this methodology the results from the HPDC process simulations are used to modify the material model and the fracture criterion in the Finite Element Analysis (FEA). This paper focuses on the simulation of the HPDC process for thin-walled magnesium components. The close connection between the processing history and the mechanical properties of the casting mandates a careful analysis of the key factors influencing the final part performance. The definition of the boundary and initial conditions will strongly influence the ability to predict important features in the microstructure of the casting and consequently the final mechanical properties of the casting.