International Journal of Arts and Sciences 3(9): 320-325 (2010) CD-ROM. ISSN: 1944-6934 © InternationalJournal.org Investigation the Effects of Process Parameters on Product Quality in Cold Chamber High Pressure Die Casting of Magnesium Alloys Ali Serdar Vanli, Yildiz Technical University, Turkey Anil Akdogan, Yildiz Technical University, Turkey Huseyin Sonmez, Yildiz Technical University, Turkey Abstract: Magnesium alloys can be used for lots of sectors with its suitable characteristics especially preferred for automotive and aerospace industry because of its light weight properties. This material is slight just like the polymers but also exhibits a unique strength feature as the other metals. High pressure die casting of magnesium alloys has been the fastest grown up and the most globally developed section of the magnesium industry. Besides, in die casting industry the cold chamber process has been favored for its unique ability to transform the injected molten magnesium into an accurately dimensioned form in the shortest possible cycle time. Although high pressure die casting is a very precision process; there are lots of factors which are effective on the product quality and mechanical properties. The process parameters; casting and die temperatures, filling time, plunger and gate velocities, injection and intensification pressures, spearhead of these factors. This paper investigates the present works about the effects of process parameters on the product quality in literature. For obtain qualified casting products which have good mechanical properties and low porosity contents; the casting process should be made under high injection and intensification pressures, with low casting and high die temperatures and with minimum flow velocities. Keywords: Magnesium alloys, cold chamber die casting, process parameters, product quality. 1. Introduction Magnesium is an ultra-light structural metal, its density (1.73 gm/cm 3 ) is two-thirds that of aluminum. As a result, during the recent years, cast magnesium alloys have received considerable attention from the automotive industry for the components such as instrument panels, steering wheels, seat frames, doorframes and power train components due to potential of fuel efficiencies and lower emission levels. Magnesium alloy castings are also used in the microelectronics and telecommunications industries for disk drives, DVD chassis, and cell phones, etc. (Department of Trade and Industry 2004; Lee, Gokhale, Patel, and Evans, 2006). High pressure die casting of magnesium is a proven manufacturing process by which products are being produced in volume, from tiny electronic parts to truck transmission cases. High pressure casting is a repetitive process where identical parts are cast at high production rates by injecting molten metal under pressure into a steel die. A die casting die or mould is a closed vessel into which molten metal is injected under high pressure and temperature and then rapidly cooled until the solidified part is sufficiently rigid to permit ejection from the mould (Brungs, 1997; Friedrich and Mordike, 2006). High-pressure die casting, has the unique ability to transform the injected molten magnesium into an accurately dimensioned and smoothly finished form in the shortest possible cycle time. With similarities to the plastic injection molding process, die casting can make parts to the final shape, often with no additional machining or other operations required. Unlike plastics,