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Effect of Cooling Process on Porosity in the Aluminum Alloy Automotive Wheel During Low-Pressure Die Casting

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Abstract

Experiments were conducted to verify the feasibility of cooling process for one aluminum alloy wheel during low-pressure die casting, and the results showed there were some macroporosity defects in the junctions of small spokes. Numerical simulation was implemented, and the rational cooling and insulation process was determined by analyzing the solidification times of different stages at some locations of casting. The simulation and experimental results both demonstrated the insulation spots had a good effect on prolonging solidification time at the location with thin wall thickness, preventing the feeding paths cutoff prematurely and decreasing the size of porosity defects distinctly.

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Author information

Authors and Affiliations

  1. National Die and Mold CAD Engineering Research Center, Shanghai Jiao Tong University, Shanghai, China

    Dashan Sui & Zhenshan Cui

  2. Department of Technology Development, Dare Wheel Manufacturing Co., Ltd., Zhenjiang, Jiangsu, China

    Rong Wang & Shengfei Hao

  3. Department of Mechanical Engineering Technology, Purdue University, West Lafayette, IN, USA

    Qingyou Han

Authors
  1. Dashan Sui
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  2. Zhenshan Cui
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  3. Rong Wang
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  4. Shengfei Hao
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  5. Qingyou Han
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Corresponding author

Correspondence to Dashan Sui.

Technical Review and Discussion

Technical Review and Discussion

Effect of Cooling Process on Porosity in the Aluminum Alloy Automotive Wheel During Low Pressure Die Casting

Dashan Sui, Zhenshan Cui; Shanghai Jiao Tong University, Shanghai, China

Rong Wang, Shengfei Hao; Dare Wheel Manufacturing Co., Ltd., Zhenjiang, Jiangsu, China

Qingyou Han; Purdue University, West Lafayette, IN, USA

Reviewers:

It would be helpful to have more description about what kind of thermocouples with what response time etc. were used, as it can impact the actual temperature versus time results.

Authors:

K-type thermocouples were used to measure the temperature of dies, with a response time of 0.5 s.

Reviewers:

More data collection and simulation correlation are needed. Correlation should consider collecting data over several shots and simulating those conditions along with analyzing the castings for each shot.

Authors:

Actually, 100 wheels were produced according to scheme No. 3. The data collected for each shot were similar after 20th cycle. We reported the stable data in the paper.

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Sui, D., Cui, Z., Wang, R. et al. Effect of Cooling Process on Porosity in the Aluminum Alloy Automotive Wheel During Low-Pressure Die Casting. Inter Metalcast 10, 32–42 (2016). https://doi.org/10.1007/s40962-015-0008-0

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  • DOI: https://doi.org/10.1007/s40962-015-0008-0

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