Simulation and Experimental Validation of Secondary Dendrite Arm Spacing for AlSi7Mg0.3 Chassis Parts in Low Pressure Die Casting

Vergnano, Alberto; Bergamini, Umberto; Bianchi, Daniele; Veronesi, Paolo; Spagnolo, Roberto; Leali, Francesco

doi:10.1007/978-3-030-70566-4_6

Cited by 3 publications

(4 citation statements)

References 7 publications

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“…Higher cooling rate will reduce the solidification time, and will also reduce the SDAS parameter which will improve the mechanical properties of the aluminium alloy. This statement is acknowledged by other authors [ 27 , 28 , 29 , 30 ]. As study [ 26 ] describes that SDAS is approximately equivalent to the third root of the solidification time.…”

Section: Introductionmentioning

confidence: 81%

Determination of linear expansion of AlSi10Mg aluminium alloy depending on external conditions during solidification

Radkovský

Gawronová²,

Válková³

et al. 2022

Heliyon

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Section: Introductionmentioning

confidence: 81%

Determination of linear expansion of AlSi10Mg aluminium alloy depending on external conditions during solidification

Radkovský

Gawronová²,

Válková³

et al. 2022

Heliyon

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“…The process cycle time is considered from the simulation of each sized design case, resulting from the die open condition after complete alloy solidification. The SDAS is calculated with (6) with the coefficients k = 1.852 and n = 0.5735, since these were previously identified for the same material [33]. For example, Figure 7 reports the solidification times and the SDAS in the critical zones for case 3a.…”

Section: Evaluation Of the Design Casesmentioning

confidence: 90%

“…As a rule of thumb, the SDAS is approximately proportional to the cube root of the solidification time, i.e. the value of n ≈ 0.33, [33,36]. A higher heat removal rate would reduce the solidification time, thus reducing the SDAS and consequently improving the Al alloy strength.…”

Section: Secondary Dendrite Arm Spacing Evaluationmentioning

confidence: 99%

“…The grain size of the Al alloy has to be as small as possible in order to obtain good mechanical properties, as the yield strength [30] and the ultimate tensile strength [31,32] are inversely proportional to the square root of the grain size. Thus, for production quality control, the expected Al alloy strength is indirectly verified by measuring the grain size as Secondary Dendrite Arm Spacing (SDAS) on micrographs of polished and etched samples [33]. The SDAS values in critical zones are so important, also affecting the occurrence of defects, that they are usually set as contract specifications with the foundry.…”

Section: Introductionmentioning

confidence: 99%

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A method for yield and cycle time improvements in Al alloy casting with enhanced conductivity steel for die construction

et al. 2022

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A die for Al alloy casting must be designed to achieve the expected quality levels. Moreover, the casting unit cost must be regarded as the objective function to be minimised. It can be expressed as a function of the quantity of materials and energy to be used, cycle time and equipment investment. This work compares the performance of the die with inserts manufactured using the usual 1.2343 steel with that of the innovative 1.2383. The latter is considered due to its enhanced thermal conductivity, despite being more expensive. Simulation experiments are designed to evaluate different die layouts. The quality design solutions are evaluated against the cost objective function in order to identify the optimal die choice. A case study on gravity die casting (GDC) of an AlSi7Mg0.3 engine head shows faster solidification dynamics when using 1.2383 instead of 1.2343 steel. This reduces the feeder volume, thus increasing the production yield and speeding up the cycle time with a leverage effect. The higher investment cost for the inserts is rapidly returned thanks to the reduction in variable costs. The Return On Investment (ROI) with the improved die in the new solution is short compared with the life of the die.

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Robustness Assessment in the Optimization of Low-Pressure Die Casting Subject to Variations in Secondary Alloy Composition

Vergnano,

Rezvanpour,

Spessotto

et al. 2024

Inter Metalcast

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Porosity is a significant factor affecting the final mechanical properties in aluminum casting. Therefore, minimizing porosity by optimizing the casting parameters is of great importance. However, during normal production, some variability must be considered for these parameters, especially when using secondary alloys. Variations in alloy composition can greatly influence the solidification process, microstructure, and the product’s mechanical properties. Accordingly, achieving a robust design that accounts for secondary alloy composition variations is crucial to ensure the consistent quality and performance of the cast parts. This research uses a car wheel as a case study for a low-pressure die casting process. An optimization process is then conducted using a genetic algorithm (GA) to refine casting parameters such as heat transfer coefficient (HTC) and initial pouring temperature. Finally, the results are analyzed using the signal-to-noise ratio and the Taguchi quality loss function method to measure the robustness of the design sets. These results indicated that by conducting an optimization process and introducing noise factors as parameters, a robust design that withstand alloy variations can be achieved, and a design of simulation experiment can be established.

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Simulation and Experimental Validation of Secondary Dendrite Arm Spacing for AlSi7Mg0.3 Chassis Parts in Low Pressure Die Casting

Cited by 3 publications

References 7 publications

Determination of linear expansion of AlSi10Mg aluminium alloy depending on external conditions during solidification

Determination of linear expansion of AlSi10Mg aluminium alloy depending on external conditions during solidification

A method for yield and cycle time improvements in Al alloy casting with enhanced conductivity steel for die construction

Robustness Assessment in the Optimization of Low-Pressure Die Casting Subject to Variations in Secondary Alloy Composition

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