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Ultra-large aluminum shape casting: Opportunities and challenges

Time：2024-11-29　　　Hits：2285

Title: Ultra-large aluminum shape casting: Opportunities and challenges

DOI: https://doi.org/10.1007/s41230-024-4111-9

Author: *Qi-gui Wang, Andy Wang, and Jason Coryell

*Qi-gui Wang

Ph. D. Fellow of ASM International, a Lead Technical Specialist at General Motors Global Powertrain Engineering. He received his M.S. in 1987 from Southeast University, China and his Ph. D. in 1997 in Materials Engineering from the University of Queensland in Brisbane, Australia. During past 30 years, Dr. Wang has developed a strong expertise in numerous areas related to metal casting. He has also made distinguished and sustained contributions to the applied and theoretical understanding of fracture and fatigue of castings, as well as pioneering the development of computational models that linking processing, microstructure and properties in aluminum automotive powertrain components. Dr. Wang is an author of over 120 technical papers and 60 patents and patent applications.

E-mail: qigui.wang@gm.com

Abstract:

Ultra-large aluminum shape castings have been increasingly used in automotive vehicles, particularly in electric vehicles for light-weighting and vehicle manufacturing cost reduction. As most of them are structural components subject to both quasi-static, dynamic and cyclic loading, the quality and quantifiable performance of the ultra-large aluminum shape castings is critical to their success in both design and manufacturing. This paper briefly reviews some application examples of ultra-large aluminum castings in automotive industry and outlines their advantages and benefits. Factors affecting quality, microstructure and mechanical properties of ultra-large aluminum castings are evaluated and discussed as aluminum shape casting processing is very complex and often involves many competing mechanisms, multi-physics phenomena, and potentially large uncertainties that significantly influence the casting quality and performance. Metallurgical analysis and mechanical property assessment of an ultra-large aluminum shape casting are presented. Challenges are highlighted and suggestions are made for robust design and manufacturing of ultra-large aluminum castings.

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Yu-dong Sui, Ye-hua Jiang, and Qu-dong Wang（昆明理工大学）

DOI: https://doi.org/10.1007/s41230-022-1076-4

Fabrication and compressive behavior of open-cell aluminum foams via infiltration casting using spherical CaCl₂ space-holders

利用球形CaCl₂颗粒渗流制备开孔泡沫铝及其压缩性能研究（Vol. 19 No. 2, 2022）

Tan Wan, Gang-qiang Liang, Zhao-ming Wang, Can-xu Zhou, and Yuan Liu（清华大学）

DOI: https://doi.org/10.1007/s41230-022-1159-2

Simulation of α-Al grain formation in high vacuum die-casting Al-Si-Mg alloys with multi-component quantitative cellular automaton method

基于多元量化元胞自动机法的高真空压铸Al-Si-Mg合金α-Al晶粒的形成模拟（Vol. 19 No. 2, 2022）

Yong-zhi Hao, Hai-dong Zhao, Xu Shen, Xue-ling Wang, and Hui-ting Zheng（华南理工大学）

DOI: https://doi.org/10.1007/s41230-022-1176-1

Efficient fabrication of semisolid nondendritic Al alloy slurry with high quality

高效率制备高质量非枝晶半固态铝合金浆料（Vol. 19 No. 2, 2022）

Zong-xu Zhang, Ti-jun Chen, Kun Liu, Han Xue, Jia-chen Qi, Guang-li Bi, and Ying Ma（兰州理工大学）

DOI: https://doi.org/10.1007/s41230-022-1134-y

An Al-12Si/ZnS powder inoculant for eutectic silicon in Al-12Si alloy

用于Al-12Si合金中共晶硅的一种Al-12Si/ZnS粉末孕育剂（Vol. 19 No. 2, 2022）

Ying Wang, Pan-yu Chen, Yu-hui Lin, Mei Zhao, and Cheng-dong Li（青岛科技大学）

DOI: https://doi.org/10.1007/s41230-022-9003-2

Effects of cooling rates on microporosity in DC casting Al-Li alloy

冷却速率对半连续铸造Al-Li合金显微缩松的影响（Vol. 19 No. 2, 2022）

Yu-xuan Zhang, Jun-sheng Wang, Dong-xu Chen, Bing Wang, Chi Zhang, and Zheng-an Wang（北京理工大学）

DOI: https://doi.org/10.1007/s41230-022-1183-2

Structures and macrosegregation of a 2024 aluminum alloy fabricated by direct chill casting with double cooling field

双冷场半连铸2024铝合金的组织与宏观偏析（Vol. 19 No. 1, 2022）

Cheng Zhu, Zhi-hao Zhao, Qing-feng Zhu, Gao-song Wang, Yu-bo Zuo, and Gao-wu Qin（东北大学）

DOI: https://doi.org/10.1007/s41230-022-1030-5

Effects of Zr additions on structure and tensile properties of an Al-4.5Cu-0.3Mg-0.05Ti (wt.%) alloy

Zr对Al-4.5Cu-0.3Mg-0.05Ti (wt.%)合金组织和拉伸性能的影响（Vol. 19 No. 1, 2022）

Hamed Kamali, Erfan Kamali, and Massoud Emamy（德黑兰大学，伊朗）

DOI: https://doi.org/10.1007/s41230-022-1094-2

Regulative effect of Mg/Si ratio on microstructure evolution and mechanical properties of cast Al-Li-Mg-Si alloys

Mg/Si比对铸态Al-Li-Mg-Si合金组织演变和力学性能的协同调控作用（Vol. 19 No. 1, 2022）

Xue-jian Zhang, Hong-wei Wang, Feng-bai Ye, Chun-ming Zou, and Zun-jie Wei（哈尔滨工业大学）

DOI: https://doi.org/10.1007/s41230-022-1105-3