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Accurate Simulation of Complex Temperature Field in Counter-Pressure Casting Process Using A356 Aluminum Alloy

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Abstract

Automobile steering knuckle is an important part of the steering system, which is subjected to significant impacts and loads during its operation. Generally, cast aluminum steering knuckles are usually produced using some type of enhanced low-pressure casting process, like counter-pressure casting. Compared with aluminum forging and sand cast ductile iron, it can improve the production speed and achieve the adequate casting quality. In this study, various methodologies such as dynamic thermomechanical analysis, differential scanning calorimetry, and the laser flash method were employed to study the thermophysical properties of AlSi7Mg0.3. Further, the physical model of a counter-pressure casting system with an aluminum interior was established based on the combination of the tested and the theoretical properties of aluminum; this was achieved with the consideration of the presence of other factors including rapid solidification. The temperature field of the system was computed and verified by thermocouples at six different points during the tooling and the shrinkage simulation. It was observed that the plot shape of the computed temperatures and that of the simulated ones correlated; further, the difference between the peaks and the valleys was controlled to be 3% on an average, with the maximum variation of 7% at only one point. Moreover, all the predicted shrinkages were verified by the casting. This study provides a solid foundation for facilitating the simulation of the morphologies of the microstructure.

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Funding

Funding was provided by 上海市“创新行动计划”基础研究项目 (Grant Nos. 17JC1400600, 17JC1400603) and 中国国家工信部绿色再制造项目 (Grant No. 先进涡轮发动机热端部件绿色关键工艺系统集成).

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Authors and Affiliations

  1. Research Center of High-Temperature Alloy Precision Forming, School of Materials Engineering, Shanghai University of Engineering Science, Shanghai, 201620, China

    Yuncan Tian, Dongye Yang, Mengqi Jiang & Bo He

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  1. Yuncan Tian
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  2. Dongye Yang
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  3. Mengqi Jiang
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  4. Bo He
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Correspondence to Bo He.

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Tian, Y., Yang, D., Jiang, M. et al. Accurate Simulation of Complex Temperature Field in Counter-Pressure Casting Process Using A356 Aluminum Alloy. Inter Metalcast 15, 259–270 (2021). https://doi.org/10.1007/s40962-020-00456-9

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  • DOI: https://doi.org/10.1007/s40962-020-00456-9

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