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<p>The manufacturing of molded deep cavity magnesium matrix composite components presents considerable challenges for the casting industry. The main difficulty arises from the increase in melt viscosity after SiC particles are added, which reduces fluidity. This reduction in fluidity complicates mold filling and can lead to porosity and other defects. In this study, composite cylindrical components were produced using a melt agitation-assisted pressure casting technique. The components had an inner diameter (<i>d</i>) of 190&#xa0;mm, an outer diameter (<i>D</i>) of 220&#xa0;mm, and a height (<i>H</i>) of 300&#xa0;mm. The optimal casting process was determined through the use of casting simulation software, comparing the porosity results from various processes. The components produced using this method were fully formed, with their profile and dimensions conforming to the design specifications. Microstructural analysis indicated that SiC particles were well-dispersed and separated within the magnesium matrix, with the grain size distribution being symmetrical around the average value. Tensile testing revealed that that the tensile strength was 337.0&#xa0;MPa, the elongation was 2.7%, and the modulus was 60&#xa0;GPa. The integration of numerical simulation and casting technologies led to significant improvements in microstructure, density, and mechanical properties of the deep cavity cylindrical components, resulting in high-quality, large, and complex magnesium matrix composite components.</p>

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Casting Simulation and Advanced Manufacturing of Deep Cavity Cylindrical Components with Magnesium-Based Materials

  • 期刊论文

  • 发表日期：

    2025年5月8日

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  • Mingjie Shen,
  • Hua Yang,
  • Jingya Wang,
  • Xiangzhen Xue

摘要

The manufacturing of molded deep cavity magnesium matrix composite components presents considerable challenges for the casting industry. The main difficulty arises from the increase in melt viscosity after SiC particles are added, which reduces fluidity. This reduction in fluidity complicates mold filling and can lead to porosity and other defects. In this study, composite cylindrical components were produced using a melt agitation-assisted pressure casting technique. The components had an inner diameter (d) of 190 mm, an outer diameter (D) of 220 mm, and a height (H) of 300 mm. The optimal casting process was determined through the use of casting simulation software, comparing the porosity results from various processes. The components produced using this method were fully formed, with their profile and dimensions conforming to the design specifications. Microstructural analysis indicated that SiC particles were well-dispersed and separated within the magnesium matrix, with the grain size distribution being symmetrical around the average value. Tensile testing revealed that that the tensile strength was 337.0 MPa, the elongation was 2.7%, and the modulus was 60 GPa. The integration of numerical simulation and casting technologies led to significant improvements in microstructure, density, and mechanical properties of the deep cavity cylindrical components, resulting in high-quality, large, and complex magnesium matrix composite components.