Recent developments and applications of rheo-diecast components for transportation markets are described. The components have been produced using the SEED (Swirled Enthalpy Equilibrium Device) semi-solid process. The development process typically involves several steps, including (1) an evaluation (and modification) of the component design to ensure it is suitable for semi-solid die casting, (2) the use of flow and solidification simulation to optimize the layout of the gating system, and to ensure that the modified component design can be produced without filling turbulence and shrinkage porosity, (3) stress modeling to ensure that the redesigned component will meet performance targets, and (4) in-plant development of the optimum process parameters. This development process will be described in detail for several commercial components, including two brackets for trucking applications, and connectors used in the frame of an electric bus.
Trace elements Sc was added to the Al-Zn-Mg-Cu-Zr alloys, the differences of the microstructure and properties using gravity casting and squeeze casting are compared. The result shows that through the addition of trace elements Sc, the Al-Zn-Mg-Cu-Zr alloys casting microstructure was refined effectively, dendrite segregation was alleviated and the mechanical property of alloy was enhanced. Using squeeze casting forming could improve the compactness of the alloys, decrease the probability of occurrence of shrinkage cavities, porosity and segregation, in addition, the grain could be refined by the pressure forced on the alloy melt. Combined the element Sc microalloying and squeeze casting used in Al-Zn-Mg-Cu-Zr alloy forming, we could get the casting with uniform, compact, little defect microstructures. This combination could provide a new way to the Al-Zn-Mg-Cu-Zr alloy forming.
The effect of heat treatment on vacuum die-casting (VDC) AT72 magnesium alloy was studied. The optimal process of heat treatment was obtained. The result shows that the alloy was composed of α-Mg, Mg17Al12and Mg2Sn. After solution treatment at 686K for 24h, Mg17Al12completely dissolved in α-Mg matrix. With the aging treatment following solution treatment, Mg17Al12kept precipitating in the matrix and along grain boundary. Moreover, Mg2Sn distributed along the grain boundary did not disappear after solution treatment at 686K. This indicates that Mg2Sn phase exhibits very high thermal stability. The heat treatment process was optimized with solution at 686K for 24h plus ageing at 473K for 18h, in the condition of which AT72 magnesium alloy exhibits a maximum hardness with value of 90.8Hv. The successful application of heat treatment for AT72 magnesium alloy could be attributed to the elimination of the air bubble in the casing through VDC. However, the porosity in the cast couldnt be efficiently eliminated by VDC, which result in the growth of shrinkage pore.
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.
The solidification process and microstructure of Al-7Si-0.3Mg alloy with different rare earth (RE) additions have been studied by using thermal analysis, optical microscopy (OM), scanning electron microscopy (SEM) and X-ray diffraction (XRD) analysis. The results showed that the addition of RE enhanced the liquidus temperature and decreased the growth temperature of eutectic Si, which lead to obvious increase in solidification interval of the studied alloy. In addition, the grain size of primary α-Al had no obvious change, and the mean area of eutectic Si particles decreased with increasing RE content to 1.6 wt.%. The RE-rich compounds with different compositions were obtained with increasing RE concentration in Al-7Si-0.3Mg alloys. The method of phase diagram calculation helps to clarify the formation and growth mechamism of different RE-rich phases during solidification.
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