Applications of Squeeze Casting for Automobile Parts

Abstract

With an increasing pressure on automotive weight reduction, the demand on the lighter weight automotive components continues to increase. In recent years, squeeze casting processes have been used with different aluminium alloys to produce high integrity automotive parts. In this study, the indirect squeeze casting processes is adopted to cast a motorcycles component originally produced by a high pressure die casting process using aluminium alloy ADC12. To minimize amount of gas porosity inside squeeze casts, concepts of (1) minimization of ingate velocity along with (2) bottom filling pattern during the die filling, and (3) maximization of intensifications casting pressure are applied. Then parts are casted with both conventional high pressure die casting and indirect squeeze casting processes. Comparative evaluation of mechanical properties was made between HPDC casts and squeeze casts both in as-cast and heat treated conditions. Results from the experiment have shown that squeeze casts can pass the blister test at 490 °C for 2.5 hours. Then, squeeze casts are heat treated by solution treatment at 484 °C for 20 minutes and artificial age at 190 °C for 2.5 hours, respectively. This improves UTS of the heat treated squeeze cast to 254.14 MPa with 1.84% of elongation, while the UTS of as cast condition from both processes is not significantly different.

Archives of Foundry Engineering

“…Owing to addition of silicon, the investigated casting alloys (AlSi7Mg, AlSi7Cu3Mg and AlSi9Cu3(Fe)) feature good casting ability and abrasion resistance, as the silicon has effect on their improvement. These alloys can be poured both into sand moulds and permanent moulds, as well as can be used in pressure die casting, and in a new technologies like thixocasting and squeeze casting [29][30][31]. These alloys are characterized by a high strength, are heat treatable (dispersion hardening) and easily welded.…”

Influence of Si, Cu, B, and Trace Alloying Elements on the Conductivity of the Al-Si-Cu Alloy

“…ADC12 is a popular pressure die-casting Al alloy because of a good combination of castability, productivity, corrosion resistance, wear resistance, mechanical properties, low price, and environment friendliness [3][4][5][6][7][8]. ADC12 has wide commercial applications such as LED lamp sockets, radiators in wireless communication stations, indoor heating, and parts in the automotive industry like the engine blocks and cylinder liners [9,10]. The power of these components has been increasing quickly, which requires an increased efficiency of heat withdrawal and requires ADC12 with increased conductivity [11,12].…”