Semi-solid Die Casting of Some Aluminum Alloys for Lightweight Automotive Components

The use of light alloys in automotive applications has been rapidly increasing in the industry as a means to reduce fuel consumption and carbon dioxide emissions. Semi-solid forming process for Al-Si based alloys, which produces near-net shape components with the desired properties and cost effectiveness satisfies the requirements in this regard. This paper explores the potential of Al-Si based alloys in semi-solid forming of truck components, which were originally casted in iron-based alloy. The Swirled Enthalpy Equilibration Device (SEED) technique was utilized to prepare semi-solid slurries of A356 and 319s. In order to improve the mechanical properties of rheo-HPDC components, various heat treatment cycles were studied. Microstructural characteristics of the alloys under different heat treatment conditions were examined using optical and scanning electron microscopy. Hardness and tensile experiments were applied to evaluate the mechanical properties of the alloys. A comparison of cost and static load performance was conducted for various materials. The findings indicate that the rheo-HPDC technique has been successful in producing Al-Si-based alloys with an optimal microstructure that combines both quality and mechanical performance.