Multi-objective optimization of process parameters during low-pressure die casting of AZ91D magnesium alloy wheel castings

Zhang, Chen; Fu, Yu; Han, Wei; Hai, Hong

doi:10.1007/s41230-018-8066-6

Cited by 12 publications

(5 citation statements)

References 8 publications

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“…The front end of the metal liquid may solidify before the filling process is complete if the pouring temperature is too low, resulting in cold shuts, misruns, and underfilling. When the temperature is too high, the metal liquid is more likely to absorb hydrogen gas from the atmosphere increasing the tendency for H2-related porosity, and the mold is subjected to more severe thermal erosion and thermal cracking, which shortens its useful life [ 24 ]. Therefore, combined with actual production experience, the selection range of control casting temperature is between 690 and 710 °C.…”

Section: Methodsmentioning

confidence: 99%

Multi-Objective Optimization of The Low-Pressure Casting of Large-Size Aluminum Alloy Wheels through a Systematic Optimization Idea

He,

Lu,

et al. 2023

Materials

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The process parameters in the low-pressure casting of large-size aluminum alloy wheels are systematically optimized in this work using numerical casting simulation, response surface methodology (RSM), and genetic algorithm (NSGA-II). A nonlinear input–output relationship was established based on the Box–Behnken experimental design (BBD) for the crucial casting parameters (pouring temperature, mold temperature, holding pressure, holding time), and response indicators (defect volume fraction, spokes large plane mean secondary dendrite spacing (SDAS)), and a mathematical model was developed by regression analysis. The Isight 2017 Design Gateway and NSGA-II algorithm were used to increase the population and look for the best overall solution for the casting parameters. The significance and predictive power of the model were assessed using ANOVA. Casting numerical simulation was used to confirm the best option. To accomplish systematic optimization in its low-pressure casting process, the mold cooling process parameters were adjusted following the local solidification rate. The results showed that the mathematical model was reliable. The optimal solutions were a pouring temperature of 703 °C, mold temperature of 409 °C, holding pressure of 1086 mb, and holding time of 249 s. The mold cooling process was further optimized, and the sequence solidification of the optimal solution was realized under the optimized cooling process. Finally, the wheel hub was manufactured on a trial basis. The X-ray detection, mechanical property analysis, and metallographic observation showed that the wheel hub had no X-ray defects and its mechanical properties were well strengthened. The effectiveness of the system optimization process scheme was verified.

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Section: Methodsmentioning

confidence: 99%

Multi-Objective Optimization of The Low-Pressure Casting of Large-Size Aluminum Alloy Wheels through a Systematic Optimization Idea

He,

Lu,

et al. 2023

Materials

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“…Cast magnesium wheels are characterized by high dimensional accuracy and lower manufacturing costs [38][39][40]. The most common types of casting used are gravity casting [41], high-pressure casting (HPC) [41], or low-pressure casting (LPC) [41][42][43][44], which is much more commonly used [15,45,46].…”

Section: Casting Of Magnesium Wheelsmentioning

confidence: 99%

“…Hollow castings are beneficial due to their structure. Studies concerning the LPC technology for the AZ91 and AM50 magnesium alloys [43][44][45] indicated that LPC castings have superior characteristics when compared with products manufactured by means of gravity casting. The work of [45] discusses simulations of the low-pressure casting of the magnesium wheel.…”

Section: Casting Of Magnesium Wheelsmentioning

confidence: 99%

Review of Magnesium Wheel Types and Methods of Their Manufacture

Dziubinska,

Siemionek,

Surdacki

et al. 2024

Materials

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This article provides a detailed review of the types of magnesium wheels available in the industry and the current methods of the wheels’ production. The past several years have seen a significant development of magnesium-based lightweight alloys employed as a structural material for modern light vehicles. Magnesium alloys are characterized by their low density while maintaining good mechanical properties. The use of these alloys in the industry enables vehicles’ weight reduction while increasing their technical parameters. The first part of the article presents the unique properties of magnesium alloys that determine the application of this material for lightweight vehicle wheels. The advantages of using magnesium wheels over aluminum wheels are also presented. Next, a classification of the types of magnesium wheels was made in regard to their construction, applications, and manufacturing methods. At present, magnesium wheels by construction can be classified according to their geometry as single parts or assembled parts. In reference to geometry, wheels can have different shapes: classic, multi-spoke, with holes, or with frames. Depending on the geometry used, magnesium wheels can have different parameters, such as their mounting hole spacing, wheel diameters, or rim width. Considering the applications in various industries, main distinctions can be made between magnesium wheels for automobiles, motorcycles, bicycles, and wheelchairs. Magnesium wheels can also be categorized in regards to the manufacturing methods: casting, machining, forging, and hybrid manufacturing. The second part of the article focuses on the analysis of magnesium alloy wheel-manufacturing technologies used in the industry and developed by research centers. This article discusses these manufacturing technologies in detail and indicates prospective directions for further development.

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“…Additionally, the adjustment of filling parameters was proposed in order to solve the problem. The authors of publication [25] attempted to optimize the parameters of the same process, in which they analyzed the parameters of low-pressure die casting. Optimal parameters were determined in order to obtain structural homogeneity, reduce shrinkage porosity, and lower dendritic segregation.…”

Section: Analysis Of Materials Used In the Manufacture Of Magnesium W...mentioning

confidence: 99%

Review of Magnesium Alloys Used in the Manufacture of Wheels for Light Vehicles

Siemionek,

Majerski,

Surdacki

et al. 2023

Adv. Sci. Technol. Res. J.

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This article provides an overview of the materials used to manufacture magnesium wheels for light vehicles. The analysis was conducted with the aim of developing a new, efficient technology for molding magnesium alloy wheels for light vehicles from preforms cast into metal molds. The knowledge accumulated so far on materials and their properties for the production of magnesium wheels will allow the design of a new technology for molding rims from materials of superior quality and durability. Currently, magnesium wheels are mainly produced from cast magnesium alloys and magnesium alloys for forming. Cast magnesium alloys used for magnesium wheels include AZ91, AM50, AM60, AE44, ZK61, ZE41, EZ33, EQ21, WE43 and the newly developed Mg-2.96Nd-0.21Zn-0.39Zr alloy. Magnesium metal-forming alloys used for magnesium wheels include AZ31, AZ61, AZ80 and ZK30, ZK60. The study includes an analysis of their properties and application examples.

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Multi-objective optimization of process parameters during low-pressure die casting of AZ91D magnesium alloy wheel castings

Cited by 12 publications

References 8 publications

Multi-Objective Optimization of The Low-Pressure Casting of Large-Size Aluminum Alloy Wheels through a Systematic Optimization Idea

Multi-Objective Optimization of The Low-Pressure Casting of Large-Size Aluminum Alloy Wheels through a Systematic Optimization Idea

Review of Magnesium Wheel Types and Methods of Their Manufacture

Review of Magnesium Alloys Used in the Manufacture of Wheels for Light Vehicles

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