New Trends in Aluminum Die Casting Alloys for Automotive Applications

Tanya
, A. BASER,; UMAY, Elif; AKINCI, Volkan

doi:10.55549/epstem.1227541

Cited by 10 publications

(5 citation statements)

References 10 publications

(16 reference statements)

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“…This compositional supercooling effect promotes the formation of the La precipitate phase, suppresses the formation of α-Al, and achieves the grain refinement effect. The growth restricting factor (GRF) represents the influence of solutes on grain refinement, and its formula is shown in Equation (1), where mi, C0, and ki are the liquidus slope, initial solute concentration, and partition coefficient, respectively. In Al-La alloy, the mLa and kLa values are known to be −2.034 and 0.003, respectively, and the GRF of 0.5 wt% La added was calculated to be 2.028, which was 0.186 higher than that of the La-free alloy [23,24].…”

Section: Resultsmentioning

confidence: 99%

“…In addition, these alloys have exceptional productivity, superior mechanical properties, and an aesthetically pleasing surface finish, making them suitable for mass production. Recently, the automobile industry has been focusing on developing eco-friendly cars and is primarily using Al–10%Si–2%Cu alloys [ 1 , 2 ]. However, Al–Si–Cu alloys used in die casting have poor corrosion resistance caused by galvanic corrosion due to potential differences with the α-Al phase, including the Al 2 Cu precipitated phase [ 3 ].…”

Section: Introductionmentioning

confidence: 99%

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Enhancement of the Corrosion Properties of Al–10%Si–2%Cu Alloys with La Addition

Kim,

Heo,

Yang

et al. 2024

Materials

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Al–10%Si–2%Cu alloys have been widely used in high-value industries (e.g., aerospace and automobiles) because of their lower specific gravity; however, galvanic corrosion rendered these alloys to have poor corrosion resistance. Therefore, the microstructure and corrosion properties of Al–10%Si–2%Cu alloys were investigated with respect to the lanthanum (La) content. All Al alloy samples were synthesized using gravity casting, with added La contents of 0.00, 0.25, 0.50, 0.75, and 1.00 wt%, and were characterized using microstructural characteristics analysis and electrochemical tests. Adding 0.5 wt% La (xLa-0.5) indicated the finest structure, which had a 4% lower α-Al area fraction than the La-free alloy (xLa-0). However, the area fraction of a 1 wt% La-added (xLa-1) alloy was 2.4% higher than that of xLa-0. The corrosion current density (Icorr) of the xLa-0.5 was 1.09 μA/cm2, representing a 68% decrease as compared to that of xLa-0, and xLa-0.5 reached the highest polarization resistance value (7.32 × 103 Ω·cm2). The improvement in corrosion resistance of xLa-0.5 was due to the rapid and dense formation of a passivation layer induced by its fine structure, as well as the precipitated phase by enhancing the dispersibility of Cu.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Enhancement of the Corrosion Properties of Al–10%Si–2%Cu Alloys with La Addition

Kim,

Heo,

Yang

et al. 2024

Materials

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“…The automotive industry witnessed a significant shift with the emergence of gigacasting, a revolutionary approach pioneered by Tesla [1]. This technology utilises colossal, high-pressure die-casting (HPDC) machines, aptly named Giga Presses, to manufacture large, single-piece chassis components from aluminium [2,3].…”

Section: Introductionmentioning

confidence: 99%

A Method for Straightening Distorted Giga-Cast Large Thin-Walled Components

Park,

Kim

2024

Materials

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Giga-casting, a revolutionary approach for manufacturing large, single-piece car body components from aluminium, has emerged as a potential game-changer in the automotive industry. However, these large, thin-walled castings are prone to distortions during solidification and heat treatment processes. Straightening these distortions is crucial to ensure structural integrity, facilitate downstream assembly, and maintain aesthetic qualities. This paper proposes a novel method for straightening giga-cast components using a multi-pin straightening machine. The machine’s versatility stems from its ability to adapt to various geometries through multiple strategically controlled straightening pins. This paper introduces the concept of a “straightening stroke decision algorithm” to achieve precise straightening and overcome the challenges of complex shapes. This algorithm determines the stroke length for each pin, combining a polynomial model representing the global stiffness of the component with a machine learning model that captures the stiffness changes arising from the current geometry. The effectiveness of the proposed approach is evaluated through comprehensive numerical experiments using finite element analyses. The straightening performance is assessed for the straightening algorithm with different machine learning models (deep neural network and XGBoost) and compared to a traditional optimisation method. The proposed surrogate models decided the straightening strokes so that the maximum remaining distortion became 0.02% of the largest dimension of each target geometry. The results of the numerical experiment showed that the proposed straightening method is suitable for straightening distortion in large thin-walled components.

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“…Recently, polymer composites have been extensively investigated for their potential substitute for steel or other metal parts in a vehicle (Zhang & Xu, 2022). Such lightweight materials are preferred due to the extreme weight allowed in vehicles, which also contributes to the mileage it could cover from a single battery charge (Arifurrahman et al, 2018;Baser et al, 2022;Sudirja et al, 2020).…”

Section: Introductionmentioning

confidence: 99%

Heat-Absorbing Composite Strength Analysis for Electric Vehicles Battery Pack Cover

BUDIMAN,

SUDIRJA,

KALEG

et al. 2023

EPSTEM

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One of the key components of Electric Vehicles is the battery pack compartment casing, which needs to be both as light and as strong as possible to cover maximum mileage while withstand vibrations and other mechanical abuse. A layer of thermal protection is also placed to the case because a typical Lithium battery used for an EV is very sensitive to temperature. In this study, a heat-absorbing lightweight composite for the battery pack compartment casing of an electric vehicle is physically constructed and put to the test to determine its mechanical characteristics. The latent ability of organic phase change materials to absorb heat without experiencing thermal rise led to their use as fillers for the resin composite. Depending on what type and how much phase change materials are utilized, the tensile evaluation reveals that the average strength is noticeably compromised. The composite preparation techniques, including the use of carbon fiber as reinforcement material, are also briefly covered in this paper.

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New Trends in Aluminum Die Casting Alloys for Automotive Applications

Cited by 10 publications

References 10 publications

Enhancement of the Corrosion Properties of Al–10%Si–2%Cu Alloys with La Addition

Enhancement of the Corrosion Properties of Al–10%Si–2%Cu Alloys with La Addition

A Method for Straightening Distorted Giga-Cast Large Thin-Walled Components

Heat-Absorbing Composite Strength Analysis for Electric Vehicles Battery Pack Cover

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