R-HPDC Process with Forced Convection Mixing Device for Automotive Part of A380 Aluminum Alloy
The continuing quest for cost-effective and complex shaped aluminum castings with fewer defects for applications in the automotive industries has aroused the interest in rheological high pressure die casting (R-HPDC). A new machine, forced convection mixing (FCM) device, based on the mechanical stir...
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doaj-34e5bdb06a0544529bfbf7d96d689ca12020-11-24T22:36:22ZengMDPI AGMaterials1996-19442014-04-01743084310510.3390/ma7043084ma7043084R-HPDC Process with Forced Convection Mixing Device for Automotive Part of A380 Aluminum AlloyBing Zhou0Yonglin Kang1Mingfan Qi2Huanhuan Zhang3Guoming Zhu4School of Materials Science and Engineering, University of Science and Technology Beijing, Beijing 100083, ChinaSchool of Materials Science and Engineering, University of Science and Technology Beijing, Beijing 100083, ChinaSchool of Materials Science and Engineering, University of Science and Technology Beijing, Beijing 100083, ChinaSchool of Materials Science and Engineering, University of Science and Technology Beijing, Beijing 100083, ChinaSchool of Materials Science and Engineering, University of Science and Technology Beijing, Beijing 100083, ChinaThe continuing quest for cost-effective and complex shaped aluminum castings with fewer defects for applications in the automotive industries has aroused the interest in rheological high pressure die casting (R-HPDC). A new machine, forced convection mixing (FCM) device, based on the mechanical stirring and convection mixing theory for the preparation of semisolid slurry in convenience and functionality was proposed to produce the automotive shock absorber part by R-HPDC process. The effect of barrel temperature and rotational speed of the device on the grain size and morphology of semi-solid slurry were extensively studied. In addition, flow behavior and temperature field of the melt in the FCM process was investigated combining computational fluid dynamics simulation. The results indicate that the microstructure and pore defects at different locations of R-HPDC casting have been greatly improved. The vigorous fluid convection in FCM process has changed the temperature field and composition distribution of conventional solidification. Appropriately increasing the rotational speed can lead to a uniform temperature filed sooner. The lower barrel temperature leads to a larger uniform degree of supercooling of the melt that benefits the promotion of nucleation rate. Both of them contribute to the decrease of the grain size and the roundness of grain morphology.http://www.mdpi.com/1996-1944/7/4/3084forced convection mixing devicesemi-soliddie castingfluid convectionA380 aluminum alloyporositycasting defects |
collection |
DOAJ |
language |
English |
format |
Article |
sources |
DOAJ |
author |
Bing Zhou Yonglin Kang Mingfan Qi Huanhuan Zhang Guoming Zhu |
spellingShingle |
Bing Zhou Yonglin Kang Mingfan Qi Huanhuan Zhang Guoming Zhu R-HPDC Process with Forced Convection Mixing Device for Automotive Part of A380 Aluminum Alloy Materials forced convection mixing device semi-solid die casting fluid convection A380 aluminum alloy porosity casting defects |
author_facet |
Bing Zhou Yonglin Kang Mingfan Qi Huanhuan Zhang Guoming Zhu |
author_sort |
Bing Zhou |
title |
R-HPDC Process with Forced Convection Mixing Device for Automotive Part of A380 Aluminum Alloy |
title_short |
R-HPDC Process with Forced Convection Mixing Device for Automotive Part of A380 Aluminum Alloy |
title_full |
R-HPDC Process with Forced Convection Mixing Device for Automotive Part of A380 Aluminum Alloy |
title_fullStr |
R-HPDC Process with Forced Convection Mixing Device for Automotive Part of A380 Aluminum Alloy |
title_full_unstemmed |
R-HPDC Process with Forced Convection Mixing Device for Automotive Part of A380 Aluminum Alloy |
title_sort |
r-hpdc process with forced convection mixing device for automotive part of a380 aluminum alloy |
publisher |
MDPI AG |
series |
Materials |
issn |
1996-1944 |
publishDate |
2014-04-01 |
description |
The continuing quest for cost-effective and complex shaped aluminum castings with fewer defects for applications in the automotive industries has aroused the interest in rheological high pressure die casting (R-HPDC). A new machine, forced convection mixing (FCM) device, based on the mechanical stirring and convection mixing theory for the preparation of semisolid slurry in convenience and functionality was proposed to produce the automotive shock absorber part by R-HPDC process. The effect of barrel temperature and rotational speed of the device on the grain size and morphology of semi-solid slurry were extensively studied. In addition, flow behavior and temperature field of the melt in the FCM process was investigated combining computational fluid dynamics simulation. The results indicate that the microstructure and pore defects at different locations of R-HPDC casting have been greatly improved. The vigorous fluid convection in FCM process has changed the temperature field and composition distribution of conventional solidification. Appropriately increasing the rotational speed can lead to a uniform temperature filed sooner. The lower barrel temperature leads to a larger uniform degree of supercooling of the melt that benefits the promotion of nucleation rate. Both of them contribute to the decrease of the grain size and the roundness of grain morphology. |
topic |
forced convection mixing device semi-solid die casting fluid convection A380 aluminum alloy porosity casting defects |
url |
http://www.mdpi.com/1996-1944/7/4/3084 |
work_keys_str_mv |
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