A Study on Solidification Behavior of a High Pressure Die Cast Aluminum Swing Arm Using Commercial Modeling Software To Predict Porosity Level

In the automobile industry, aluminum casting is a commonly utilized production process for structural components. However, flaws in aluminum castings can lead to fatigue failures. This research study provides a thorough analysis of the design, development, construction, and testing of a swing arm made of aluminum die-cast (HPDC). The investigation primarily focuses on analyzing the solidification behavior of the swing arm, with a thorough examination of factors such as pore length, solidification time, hot spot distribution, and shrinkage porosity intensity. A commercial simulation software, Magma 5, was used to facilitate design modifications in order to address observed failures. Through design modifications, the solidification time experienced a significant reduction, resulting in a shift of hotspots away from the previously identified cracked region. In addition, substantial decreases in both porosity percentage and intensity were accomplished, confirmed through X-ray and CT scan analyses. After conducting durability testing with a Dynamometer, it was discovered that there was a significant 50% increase in fatigue life when compared to the original design.

The study highlights the significance of early-stage simulation-driven design adjustments in addressing fatigue failure in HPDC aluminum structures. It was noticed that excessive porosity levels exceeding 8% are the primary factor contributing to this issue. Suggestions involve steering clear of thicker constructions and complexities in part design to reduce porosity. It is also important to consider the location of defects in relation to surface proximity and structural stress zones.