Development of the Low-Pressure Die Casting Process for an Aluminium Alloy Part

Area of Science:

• Materials Science
• Mechanical Engineering
• Manufacturing Processes

Background:

• Steering knuckles are critical automotive safety components.
• Traditional manufacturing methods may not offer optimal weight or performance.
• Aluminum alloys present a lightweight alternative for demanding applications.

Purpose of the Study:

• To develop and validate a numerical model for low-pressure die casting (LPDC) of AlSi7Mg0.3 steering knuckles.
• To analyze filling dynamics, solidification, and shrinkage porosity in the LPDC process.
• To evaluate the mechanical and microstructural properties of LPDC-produced components.

Main Methods:

• Experimental production of six AlSi7Mg0.3 steering knuckles using LPDC.
• Numerical simulation of the LPDC process using ProCAST software.
• Mechanical testing (tensile, hardness) and microstructural analysis (porosity, optical microscopy).

Main Results:

• The numerical model accurately replicated the LPDC process for steering knuckles.
• Analysis identified key parameters influencing filling, solidification, and porosity.
• Experimental parts exhibited high quality, validated by mechanical and microstructural characterization.

Conclusions:

• The LPDC process is a suitable alternative to traditional materials like steel for producing high-quality automotive components.
• Lightweight aluminum alloys can be effectively used in demanding applications via LPDC.
• The validated numerical model aids in optimizing LPDC for complex parts.