Ultra-large aluminum shape castings have been increasingly used in automotive vehicles,particularly in electric vehicles for light-weighting and vehicle manufacturing cost reduction.As most of them are structural comp...Ultra-large aluminum shape castings have been increasingly used in automotive vehicles,particularly in electric vehicles for light-weighting and vehicle manufacturing cost reduction.As most of them are structural components subject to both quasi-static,dynamic and cyclic loading,the quality and quantifiable performance of the ultra-large aluminum shape castings is critical to their success in both design and manufacturing.This paper briefly reviews some application examples of ultra-large aluminum castings in automotive industry and outlines their advantages and benefits.Factors affecting quality,microstructure and mechanical properties of ultra-large aluminum castings are evaluated and discussed as aluminum shape casting processing is very complex and often involves many competing mechanisms,multi-physics phenomena,and potentially large uncertainties that significantly influence the casting quality and performance.Metallurgical analysis and mechanical property assessment of an ultra-large aluminum shape casting are presented.Challenges are highlighted and suggestions are made for robust design and manufacturing of ultra-large aluminum castings.展开更多
With the aid of ANSYS software, the effect of different mould external part materials on magnetic flux density and electromagnetic body force in the liquid aluminum was investigated. Calculated results showed that mag...With the aid of ANSYS software, the effect of different mould external part materials on magnetic flux density and electromagnetic body force in the liquid aluminum was investigated. Calculated results showed that magnetic flux density and electromagnetic body force in the aluminum melt are greatly increased when the external part of mould is made from A3 steel. A low-frequency electromagnetic casting 6063 aluminum alloy experiment was conducted in the laboratory with the current value of 120 A and frequency value of 15 Hz. The experiment showed that the microstructure and surface quality of ingots with mould outer part made from A3 steel under low-frequency electromagnetic field are better than that of ingots with mould outer part made from austenitic stainless steel. The surface of the ingots with mould outer part made from A3 steel is smooth and free from exudations and cold shut defects. The as-cast microstructure consists of fine, uniformly distributed equiaxed grains.展开更多
A new composite material consisting of lxxx aluminum alloy and 7xxx aluminum alloy was produced by semi-continuous casting. Macrostructure, microstructure, composition distribution and hardness distribution of composi...A new composite material consisting of lxxx aluminum alloy and 7xxx aluminum alloy was produced by semi-continuous casting. Macrostructure, microstructure, composition distribution and hardness distribution of composite interface were analyzed. Macrostructure shows that composite interface is planar and clean with little evidence of porosity; microstructure shows that composite interface is a kind of metallurgical bonding; composition and hardness distributions have a good corresponding relationship. At the same time, the mechanical property of composite interface was measured, the tensile strength is 71 MPa, the shearing strength is 62 MPa and the bending strength is 142.5 MPa, which can also show that composite interface is a kind of metallurgical bonding. Temperature distribution of composite interface was obtained by measuring temperatures near composite interface in lxxx aluminum alloy.展开更多
文摘Ultra-large aluminum shape castings have been increasingly used in automotive vehicles,particularly in electric vehicles for light-weighting and vehicle manufacturing cost reduction.As most of them are structural components subject to both quasi-static,dynamic and cyclic loading,the quality and quantifiable performance of the ultra-large aluminum shape castings is critical to their success in both design and manufacturing.This paper briefly reviews some application examples of ultra-large aluminum castings in automotive industry and outlines their advantages and benefits.Factors affecting quality,microstructure and mechanical properties of ultra-large aluminum castings are evaluated and discussed as aluminum shape casting processing is very complex and often involves many competing mechanisms,multi-physics phenomena,and potentially large uncertainties that significantly influence the casting quality and performance.Metallurgical analysis and mechanical property assessment of an ultra-large aluminum shape casting are presented.Challenges are highlighted and suggestions are made for robust design and manufacturing of ultra-large aluminum castings.
基金The project (G199906490501) was supported by the National Key Fundamental Research and Development Program of China
文摘With the aid of ANSYS software, the effect of different mould external part materials on magnetic flux density and electromagnetic body force in the liquid aluminum was investigated. Calculated results showed that magnetic flux density and electromagnetic body force in the aluminum melt are greatly increased when the external part of mould is made from A3 steel. A low-frequency electromagnetic casting 6063 aluminum alloy experiment was conducted in the laboratory with the current value of 120 A and frequency value of 15 Hz. The experiment showed that the microstructure and surface quality of ingots with mould outer part made from A3 steel under low-frequency electromagnetic field are better than that of ingots with mould outer part made from austenitic stainless steel. The surface of the ingots with mould outer part made from A3 steel is smooth and free from exudations and cold shut defects. The as-cast microstructure consists of fine, uniformly distributed equiaxed grains.
基金supported by Major State Basic Research Project of China (GrantNo.2005CB623707)
文摘A new composite material consisting of lxxx aluminum alloy and 7xxx aluminum alloy was produced by semi-continuous casting. Macrostructure, microstructure, composition distribution and hardness distribution of composite interface were analyzed. Macrostructure shows that composite interface is planar and clean with little evidence of porosity; microstructure shows that composite interface is a kind of metallurgical bonding; composition and hardness distributions have a good corresponding relationship. At the same time, the mechanical property of composite interface was measured, the tensile strength is 71 MPa, the shearing strength is 62 MPa and the bending strength is 142.5 MPa, which can also show that composite interface is a kind of metallurgical bonding. Temperature distribution of composite interface was obtained by measuring temperatures near composite interface in lxxx aluminum alloy.
