Correlation between melt quality and machinability of Al9Si3Cu HPDC alloy

High-pressure die casting is the most suitable method for mass production of Al–Si alloys. The cast parts are typically subjected to machining for the final finish. In this work, the cutting tool life was investigated with regard to the melt quality. The melt cleanliness is defined by reduced pressure test and bifilm index was measured. Since bifilms are oxides, the tool life can significantly be affected by the presence of bifilms in the cast part. The study was carried out with four different melt cleanliness. Sixteen cutting tools were changed after 10000 parts for the castings with bifilm index higher than 200 mm. When bifilm index was decreased to 20 mm, the tool life was increased to an average of 4500 parts and totally four cutting tools were changed in 12000 parts.