According to its structure

the die casting process of aluminum alloy heat sink was designed

and then simulated by Flow-3 Dsoftware.The results reveal that gas-entrapped defects can be observed in its four edges of part bottom.Crack detection and sectioning observation on the test-piece of the trialproduction show that the simulated results are well consistent with practical observation

where many blowholes and pinholes can be observed in the edge parts.Process optimization was carried out to adjust the size of ingate.Its results show that the defects can be eliminated effectively.Based on the optimized process

the samples were produced.The results are well in agreement with the simulated ones

where blowholes and pinholes are eliminated greatly

meeting application requirements and reducing the defective rate.