Nowadays the automotive industry is mainly focused on competition, and this fact forces vehicle producers to constantly look for improvements in the areas of quality and reliability. Life-span, flawless operation, and safety are directly interconnected. Therefore, much attention and resources are spent on research factors that affect the stated properties. Significant capital is invested in the optimization of the constructional solutions and innovative material applications related to the safety and durability of the constructions. This paper presents the results obtained while developing a new ecological three-wheeled vehicle. The main research areas were focused on replacing the original material with a light aluminum alloy, while achieving a substantial improvement in drivability for the three-wheeled vehicle by implementing a modified front wheel steering system. The submitted research achieved a weight reduction of the frame by 40 kg by applying light material substitution (EN AW 6063.T66), which will naturally have a positive impact on the range of the designed electric vehicle; furthermore, we implemented an innovative steering mechanism optimized during the experimental operations.
ELIMINATION OF NEGATIVE EFFECT OF Fe IN SECONDARY ALLOYS AlSi6Cu4 (EN AC 45 000, A 319) BY NICKEL ROLA Ni W ELIMINOWANIU SZKODLIWEGO WPŁYWU FAZ ZAWIERAJĄCYCH Fe W STOPACH WTÓRNYCH AlSi6Cu4(EN AC 45 000, A 319)Submitted article deals with influence of iron based phases segregation by nickel, which is in literature known as iron based phases corrector. Iron is one of the most common impurities that can be found in Al-Si alloys. It is impossible to remove iron from melt by standard operations, but it is possible to eliminate iron negative effects by addition of other elements, that enables segregation of iron in form of intermetallics with less harmful effect. For melt treatment was selected an exact alloy with requested iron content -master alloy AlNi20. Influence of nickel was evaluated quantitatively by chemical analysis (solubility), thermal analysis and microstructure evaluation. Experimental results analysis shows a new view on solubility of iron based phases during melt preparation and treatment with higher iron content and also nickel effect as iron corrector of iron based phases. It can be concluded that nickel did not influenced iron based phases (β-phases), it does not change their type into more favorable form. As an initial impulse for starting this work was insufficient theoretical knowledge of usage secondary alloys Al-Si-Cu with higher iron content and its appropriate elimination in process of castings production for automotive industry. Increased iron content in alloys causes segregation of iron phases in various shapes and types during solidification, which subsequently affects quality, soundness and lifetime of castings. Because of increased demands for casting quality, final mechanical properties and effort to reduce costs, it is necessary to look for compromises in casting production from secondary alloys with occurrence of various impurities.Keywords: Iron based phases, thermal analysis, iron based phases correctors, nickelArtykuł opisuje wpływ dodatku niklu do stopów wtórnych Al-Si-Cu na segregację faz zawierających żelazo, które jest jednym z najpowszechniej występujących zanieczyszczeń w tych stopach. Powszechnie wiadomo, iż nie jest możliwe usunięcie żelaza z kąpieli metalowej, natomiast można ograniczać negatywny jego wpływ poprzez związanie żelaza w fazach między-metalicznych mniej szkodliwych niż fazy β Fe, np. w następstwie dodatku innych pierwiastków. W badaniach do obróbki kąpieli zastosowano zaprawę AlNi20 z dokładnie określoną zawartością żelaza. Oddziaływanie niklu na skład i morfologię faz żelazowych określano na drodze analizy chemicznej (badania rozpuszczalności), analizy termicznej i oceny struktury. Na podstawie wyników badań stwierdzono, iż w badanych stopach nikiel nie wywiera wpływu na zmianę składu fazy β Fe, nie zmienia również kształtu jej wydzieleń do postaci bardziej korzystnej z punktu widzenia wpływu na właściwości.
The paper deals with the impact of technological parameters on the heat transfer coefficient and microstructure in AlSi12 alloy using squeeze casting technology. The casting with crystallization under pressure was used, specifically direct squeeze casting method. The goal was to affect crystallization by pressure with a value 100 and 150 MPa. The pressure applied to the melt causes a significant increase of the coefficient of heat transfer between the melt and the mold. There is an increase in heat flow by approximately 50% and the heat transfer coefficient of up to 100-fold, depending on the casting conditions. The change in cooling rate influences the morphology of the silicon particles and intermetallic phases. A change of excluded needles to a rod-shaped geometry with significantly shorter length occurs when used gravity casting method. By using the pressure of 150 MPa during the crystallization process, in the structure can be observed an irregular silica particles, but the size does not exceed 25 microns.
Porosity is one of the major defects in aluminum castings and results in a decrease of the mechanical properties of Al-Si alloys. It is induced by two mechanisms: solidification shrinkage and gas segregation. One of the methods for complex evaluation of macro and micro porosity in Al-Si alloys is using the Tatur test technique. This article deals with the evaluation of porosity with the help of Tatur tests for selected Al-Si alloys. These results will be compared with results obtained from the ProCAST simulation software.
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