Structure Optimization of Semi-Solid Die Cast Steering Knuckle and its Experiment Verification

2022 ◽  
Vol 327 ◽  
pp. 149-155
Author(s):  
Song Chen ◽  
Da Quan Li ◽  
Fan Zhang ◽  
Xiao Kang Liang ◽  
Jian Feng ◽  
...  
Keyword(s):  
High Performance ◽  
Die Casting ◽  
High Strength ◽  
Casting Process ◽  
Flow State ◽  
Local Flow ◽  
Experiment Verification ◽  
Die Casting Process ◽  
Semi Solid ◽  
Automotive Suspension

Steering knuckles are vital functional and structural components in automotive suspension systems, requiring high strength, high ductility, and complex shapes. In this study, an aluminum alloy knuckle with the semi-solid die casting process was developed to replace the conventional steel components. This research aims to optimize product design based on both structural simulation and casting process simulation to avoid defects and to meet mechanical requirements. Furthermore, the optimal design solutions need to be verified through the filling experiments and defect analysis. The results show that the removal of support rib located in the thick area of the shock absorber mounting arm is helpful to avoid the rewelding defects in the filling frontier of the SSM melt. Besides, the position of the steering rod is of medium thickness, and two ribs from different directions come together to support that area. Rewelding defects were detected when two ribs come together. To avoid rewelding defects in local areas of steering rod position, the ribs were reduced to uniform wall thickness. Thus, the local flow state was modified and the SSM melt was reinforced shear action. Ultimately, by controlling all the processes of the SSM die casting process, the high performance of aluminum knuckle was successfully developed.

Microstructure and Mechanical Properties of Al Alloys by Semi-Solid Processing with LSPSF Technology

2009 ◽  
Vol 628-629 ◽  
pp. 477-482 ◽  
Author(s):  
Hong Min Guo ◽  
Xiang Jie Yang ◽  
J.X. Wang
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloys ◽  
Die Casting ◽  
High Strength ◽  
Casting Process ◽  
Homogeneous Distribution ◽  
Casting Alloy ◽  
Die Casting Process ◽  
Casting Industry ◽  
Semi Solid

Rheoforming is becoming the choice of the casting industry which relies on the semi-solid slurry for high integrity structural parts. The potential of rheoforming with LSPSF (Low superheat pouring with a shear field) for aluminum alloys was investigated in the present work. High quality semi-solid slurries of a series of aluminum alloys were manufactured by LSPSF process, such as casting alloy A356, high strength alloy 201, secondary die casting alloy A380 and wrought alloy 2024, 6082 and 7075, in which the primary α-Al presented spherical, small and homogeneous distribution, especially with zero-entrapped liquid. Applications of LSPSF in high pressure die casting process and squeeze casting process were presented. Results showed that LSPSF rheoforming could improve microstructures and increase mechanical properties.

Development of Semi-Solid Die Casting Product Design and Die Design Technology for Aluminium Alloy Clamp

2016 ◽  
Vol 256 ◽  
pp. 334-339 ◽  
Author(s):  
Song Chen ◽  
Fan Zhang ◽  
You Feng He ◽  
Da Quan Li ◽  
Qiang Zhu
Keyword(s):  
Product Design ◽  
Die Casting ◽  
Casting Process ◽  
Die Design ◽  
Thick Wall ◽  
Thin Wall ◽  
Gating System ◽  
Cross Sectional ◽  
Die Casting Process ◽  
Semi Solid

Semi-solid slurry has significantly higher viscosity than liquid metal. This character of fluidity makes product design and die design, such as gating system, overflow and venting system, be different between these two die casting processes. In the present paper, taking a clamp product as an example, analyses the product optimization and die design by comparing the experimental and computational numerical simulation results. For the clamp, product structure is designed to be suitable for characters of SSM die casting process. The gating system is designed to be uniform variation of thickness, making the cross-sectional area uniformly reduce from the biscuit to the gate. This design ensures semi-solid metal slurry to fill die cavity from thick wall to thin wall. Gate position is designed at the thickest location, the gate shape of semi-solid die casting is set to be much bigger than traditional liquid casting. A good filling behaviour can be achieved by aforementioned all these design principles and it will be helpful to the intensification of pressure feeding after filling.

Numerical Simulation on the Filling Process of Rheological Die Casting and Forming Defects Analysis

2012 ◽  
Vol 192-193 ◽  
pp. 293-298 ◽  
Author(s):  
Fan Zhang ◽  
Nan Nan Song ◽  
Jun Zhang ◽  
Yong Lin Kang ◽  
Qiang Zhu
Keyword(s):  
Numerical Simulation ◽  
Die Casting ◽  
A356 Alloy ◽  
Casting Process ◽  
Solid Particles ◽  
Filling Process ◽  
Die Casting Process ◽  
Defects Analysis ◽  
Semi Solid ◽  
Forming Defects

According to semi-solid slurry rheological behavior, an apparent viscosity model of A356 alloy developed based on the Carreau model was established to simulate filling process of rheo-diecasting about automobile shock absorber parts and to compare with conventional liquid filling process. Numerical simulation results showed that the filling process of rheo-diecasting was smooth but difficult to splash, which reduced the tendency of the alloy oxidation and inclusion. Meanwhile, a certain percentage of the primary solid particles precipitated before filling and solidification shrinkage of semi-solid slurry were small. This benefited to reduce or eliminate shrinkage defects of the castings. Compared with conventional liquid die casting process, rheo-diecasting process had unique advantages in reducing the internal defects and improving mechanical properties of castings.

Multiphase modelling of the transient flow for Sn-15Pb and 357.0 alloys in semi-solid die casting process

2020 ◽  
Vol 278 ◽  
pp. 116534
Author(s):  
Wenying Qu ◽  
Daquan Li ◽  
Fan Zhang ◽  
Min Luo ◽  
Xiaogang Hu ◽  
...  
Keyword(s):  
Transient Flow ◽  
Die Casting ◽  
Casting Process ◽  
Die Casting Process ◽  
Semi Solid

Tensile Properties of Semi-Solid Die Cast AC4C Aluminum Alloy

2014 ◽  
Vol 680 ◽  
pp. 11-14
Author(s):  
Ke Ren Shi ◽  
Sirikul Wisutmethangoon ◽  
Jessada Wannasin ◽  
Thawatchai Plookphol
Keyword(s):  
Heat Treatment ◽  
Tensile Strength ◽  
Aluminum Alloy ◽  
Die Casting ◽  
Casting Process ◽  
Al Alloy ◽  
Die Cast ◽  
Die Casting Process ◽  
Semi Solid ◽  
Strength And Ductility

In this study, semi-solid Al-Mg-Si alloy (AC4C) was produced by using the Gas Induced Semi-Solid (GISS) die casting process. The tensile strength and ductility of the semi-solid die cast Al alloy (GISS-DC) after T6 heat treatment were investigated and compared with those of the conventional liquid die casting (CLDC). The microstructures of GISS-DC and CLDC observed by an optical microscopy were presented. The ultimate tensile strength (UTS) and yield strength (0.2% YS) of GISS-DC are compatible with those of the CLDC. However, the GISS-DC has better ductility than the CLDC, this may be due to the smaller and more globular primary α-Al phase and rounder shaped-Si particle microstructures presented in the GISS-DC. Common shrinkage pores and defects were also observed by SEM from the fracture surfaces of both alloys.

scholarly journals Study on microstructure and thermal conductivity of semi-solid die casting aluminum alloy

2021 ◽  
Vol 268 ◽  
pp. 01076
Author(s):  
Zengrong Hu ◽  
Xiaonan Wang ◽  
Xiaming Chen ◽  
Pengcheng Huan ◽  
Weihua Li ◽  
...  
Keyword(s):  
Thermal Conductivity ◽  
Aluminum Alloy ◽  
Die Casting ◽  
Casting Process ◽  
Mechanical And Thermal Properties ◽  
Thin Wall ◽  
Mechanical Stirring ◽  
Die Casting Process ◽  
Casting Aluminum ◽  
Semi Solid

In order to improve the comprehensive properties of casting aluminum, and to fulfill the requirements of forming thin wall fins for communication products, mechanical stirring was employed to prepare the semi-solid aluminum alloy AlSi8. communication products were produced by the semi-solid die casting process. The microstructure and mechanical and thermal properties were studied. The test results show that the microstructure of semi-solid die-casting samples changes from dendrite to globular microstructure, and the average tensile strength, elongation and thermal conductivity are 220MPa, 7% and 170 W/(m*K), respectively, which is significantly higher than that of the common die-casting samples. It was proved that the semi-solid die casting technology can be used in actual production and improve the products quality.

Development of Horizontal Reheating System for Semi-Solid Die Casting and Its Microstructure Evaluation

2005 ◽  
Vol 475-479 ◽  
pp. 377-380
Author(s):  
P.K. Seo ◽  
Byung Min Kim ◽  
Chung Gil Kang
Keyword(s):  
Die Casting ◽  
Casting Process ◽  
Complicated Shape ◽  
Forming Process ◽  
Globular Structure ◽  
Liquid Segregation ◽  
Die Casting Process ◽  
Semi Solid ◽  
Reheating Process ◽  
High Frequency Induction

The parts manufactured by die casting process usually contain liquid segregation and porosities. To solve these problems, the semi-solid forming process has been applied. The process enables material in the semi-solid state to be completely filled, and parts with the complicated shape to be fabricated by applying relatively low pressure. This process is necessary in order to control the microstructure of the billet as well as to achieve the desired semi-solid billet state. In this study, a horizontal high-frequency induction heating device which can be fabricated by semi-solid forming irrespective of a billet's size was developed. A globular structure of the reheated billet and a billet's temperature distribution during the reheating process for A356 were investigated.

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