Scholarlink

<p>High-vacuum integrated die-casting (HVPDC) is a pivotal technology for manufacturing ultra-large thin-walled castings, enabling low defect rates and optimized mechanical properties in monolithic structural components. In this study, AlSi10MnMg alloy was used as the base metal. Numerical simulation and experimental verification were employed to investigate how HVPDC process parameters influence the filling velocity field, local gas pressure, and resulting defects in ultra-thin, large-scale integrated thin-walled castings with a main wall thickness of 2 mm. The results show that the vacuum level significantly affects the casting’s gas content, oxide inclusions, and mechanical properties. When the vacuum level was reduced from atmospheric pressure to 50 mbar, the cumulative entrained air volume decreased by only 3.6%. When further reduced to 20&#xa0;mbar, it dropped sharply by 21.5%. The optimized process parameters were as follows: a vacuum level of 20 mbar, a pouring temperature of 690 °C, and a filling speed of 4.5&#xa0;m/s. Under these conditions, the rear floor panel’s integrated structural parts achieved high-quality molding, with a central yield strength of 136 MPa, a tensile strength of 270&#xa0;MPa, and an elongation rate of 10%. Ultra-high vacuum ( &lt; 50 mbar) reduces the solubility of hydrogen in the melt and the nucleation energy of gas bubbles, leading to bubble formation within 0.6772&#xa0;s during filling. These improvements significantly enhance the alloy’s mechanical properties and overall performance compared to those achieved by traditional processes.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Numerical Simulation and Defect Control of High-Vacuum Integrated Die-Casting of Large-Scale Complex Thin-Walled Aluminum Alloy Components for New Energy Vehicles

  • 期刊论文

  • 发表日期：

    2026年1月14日

查看全文
  • Jintao Yang,
  • Wanneng Liao,
  • Ang Li,
  • Zhongde Shan,
  • Shangze Wang

摘要

High-vacuum integrated die-casting (HVPDC) is a pivotal technology for manufacturing ultra-large thin-walled castings, enabling low defect rates and optimized mechanical properties in monolithic structural components. In this study, AlSi10MnMg alloy was used as the base metal. Numerical simulation and experimental verification were employed to investigate how HVPDC process parameters influence the filling velocity field, local gas pressure, and resulting defects in ultra-thin, large-scale integrated thin-walled castings with a main wall thickness of 2 mm. The results show that the vacuum level significantly affects the casting’s gas content, oxide inclusions, and mechanical properties. When the vacuum level was reduced from atmospheric pressure to 50 mbar, the cumulative entrained air volume decreased by only 3.6%. When further reduced to 20 mbar, it dropped sharply by 21.5%. The optimized process parameters were as follows: a vacuum level of 20 mbar, a pouring temperature of 690 °C, and a filling speed of 4.5 m/s. Under these conditions, the rear floor panel’s integrated structural parts achieved high-quality molding, with a central yield strength of 136 MPa, a tensile strength of 270 MPa, and an elongation rate of 10%. Ultra-high vacuum ( < 50 mbar) reduces the solubility of hydrogen in the melt and the nucleation energy of gas bubbles, leading to bubble formation within 0.6772 s during filling. These improvements significantly enhance the alloy’s mechanical properties and overall performance compared to those achieved by traditional processes.