Effects of Low-pressure Casting Processes on Shrinkage Porosity Formation in Al Alloys
Author of the article: LI Zhongyao1, WU Xuelong1, MIAO Yisheng2, XUE Chengpeng2, LANG Yuling3, KONG Decai3, MAXiaoying3, QIAO Haibo3, WANG Junsheng1,2,4
Author's Workplace:1. School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China; 2. School of Materials Science, Beijing Institute of Technology, Beijing 100081, China; 3. CITIC Dicastal Co., Ltd., Qinhuangdao 066010, China; 4. Advanced Research Institute of Multidisciplinary Science, Beijing Institute of Technology, Beijing 100081, China
Key Words:automobile wheel; low-pressure casting; Al alloy; shrinkage porosity; finite element method
Abstract:
Over 90% of passenger car wheels are made of aluminum alloys by a low-pressure casting process. Casting
defects are among the most important factors influencing the mechanical properties and service safety of automotive
wheels. Therefore, controlling casting defects effectively not only is a product quality issue but also impacts the safety of
the entire vehicle. The influence of the low-pressure casting process on shrinkage pores is systematically studied and
summarized in this paper. To predict the generation of shrinkage porosity defects in low pressure casting hubs, the effects
of process parameters such as pouring temperature, mold preheating temperature, filling rate and holding pressure on the
formation of shrinkage porosity were studied. The results show that increasing the pouring temperature and mold preheating
temperature increases the filling capacity and reduces the shrinkage porosity to a certain extent. However, overheating the
mold or a super high pouring temperature will lead to the opposite effects. In addition, slower filling at the laminar stage
significantly reduces the shrinkage porosity on the premise of successful filling, and a high holding pressure helps with
closing the pores.