Experimental And Numerical Simulation Study On Rheo-squeeze Casting Process Of7000Series Aluminum Alloy

With the development of modern society, increasingly widespread attention has been paid on environment and energy problem. For transporation vehicles, the contradiction between energy saving and environmental protection is placed in a prominent position, Lightweight of component is one of the main means to achieve energy conservation and emissions reduction. In national defense industry, lightweighting of the component also played an important role in improving the bearing capacity of the equipment and mobility under the condition without decreasing the performance of the component. In the aluminum alloys,7000series alloys have the highest strength close to the steel strength, which is considered as substitute materials instead of steel. As7000aluminum alloys are wrought alloy, the production of components and thereby performances are needed by melting, casting, deforming, and machining processes, etc. The application of the such alloys are limited to some degree due to its long process, leading to low production efficiency and material utilization, high energy consumption and cost.Currently, much research work in metal solidification field focuses on development of rheo-squeeze casting process of7000series aluminum alloys. But segregation and hot-cracking susceptibility for such alloys in the conventional casting process are not avoided due to its high alloying contents and large density difference.So it is considered to be of key importance to accurately control homogeneous composition distribution and uniformly fine microstructure during solidification.In this study, based on melt treatment technology by annular electromagnetic stirring developed by our group, a computational model on rheo-squeeze casting process of7000series high strength aluminum alloy was established, by adopting the experimental and simulation methods, effects on rheo-squeeze casting processes on solidification and formation of component were investigated and casting variables were optimized, and the results were initially applied in the production of the large-sized, complicated casting with super-high performance. It is concluded that,(1) optimization model and obtain parameters (2) by using the normal rule method and simulate shell parts designed by myself, the effects on the rheo-squeeze casting processes on casting defects were understood, and the most optimal process parameters for rheo-squeeze casting are as followed,annular electromagnetic stirring current:10A, termination temperature of stirring:670～660℃,the melt casting temperature;660℃, squeeze casting pressure:100mPa, mold temperature:200℃, squeeze casting speed:0.1m;(3) based on the above research results in the lab, and a large-sized, complicated casting with a weight of20kg was successfully produced.