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<p>Porosity in aluminium high-pressure die castings (HPDCs) often arises from restricted feeding and gas entrapment during solidification, with defects frequently concentrated around load-bearing bosses. To mitigate this limitation, SAE 1018 steel inserts were cast into ADC6 swing arms as localized thermal sinks and geometric modifiers to redirect heat flow and accelerate solidification at the pivot and muffler-mount bosses. Their influence was assessed using planar X-ray radiography and computed tomography (CT) to characterize pore distribution, together with thread-stripping torque evaluation and endurance testing on a chassis dynamometer. In comparison with the all-aluminium baseline, the insert-reinforced configuration exhibited a pronounced reduction in maximum pore volume at critical bosses, enhanced thread-retention capacity, and superior endurance life under service-simulated cycling. These outcomes confirm that strategically positioned steel inserts effectively suppress shrinkage porosity, strengthen threaded joints, and extend service life, thereby providing a production-feasible pathway to improve the durability of HPDC swing arms without additional weight penalties.</p>

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Bimetallic Insert Casting Approach to Minimize Porosity and Improve Reliability of Aluminium Swing Arm

  • 期刊论文

  • 发表日期：

    2025年9月24日

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  • Nitin Choudhari,
  • Dinesh Dhande

摘要

Porosity in aluminium high-pressure die castings (HPDCs) often arises from restricted feeding and gas entrapment during solidification, with defects frequently concentrated around load-bearing bosses. To mitigate this limitation, SAE 1018 steel inserts were cast into ADC6 swing arms as localized thermal sinks and geometric modifiers to redirect heat flow and accelerate solidification at the pivot and muffler-mount bosses. Their influence was assessed using planar X-ray radiography and computed tomography (CT) to characterize pore distribution, together with thread-stripping torque evaluation and endurance testing on a chassis dynamometer. In comparison with the all-aluminium baseline, the insert-reinforced configuration exhibited a pronounced reduction in maximum pore volume at critical bosses, enhanced thread-retention capacity, and superior endurance life under service-simulated cycling. These outcomes confirm that strategically positioned steel inserts effectively suppress shrinkage porosity, strengthen threaded joints, and extend service life, thereby providing a production-feasible pathway to improve the durability of HPDC swing arms without additional weight penalties.