1. Cov neeg tsav tsheb hauv khw
Hybrid thiab roj teeb- tsheb fais fab tau dhau los ua lub zog tseem ceeb hauv Tuam Tshoj txoj kev lag luam tsheb. Qhov loj ntxiv ntawm cov pob roj teeb ua rau lub cev -hauv-dawb (BIW) lub teeb hnyav hnyav dua li qhov qub. BIW qhov hnyav txo ua raws li ob txoj hauv kev:
ib. Siab- txoj kev muaj zog - kub- ua steels thiab siab heev - lub zog steels.
b. Tsawg- txoj kev ceev - txhuas thiab magnesium lub teeb- hlau castings.
Siab tuag-casting yog thawj txheej txheem tsim rau cov hlau teeb no. Nyob rau hauv cov txheej txheem no molten hlau raug yuam mus rau hauv ib lub pwm mus tas li nyob rau hauv lub siab, solidifying nyob rau hauv ze -net-puab qhov chaw. Rau automotive BIW Cheebtsam muaj ob qhov sib txawv:
- Tsawg- siab tuag-casting (0–0.2 MPa) - haum rau tuab- phab ntsa lossis qhov yooj yim me me; Piv txwv li, rear- ncua kev kawm ntawv brackets ua los ntawm qis- siab xuab zeb casting.
- Siab- siab tuag-casting (HPDC) - ua nyob rau ntawm qhov siab tshaj qhov siab tshaj atmospheric thiab nyob rau hauv siab plunger speeds, enabling loj, nyias- phab ntsa, complex qhov chaw thiab sawv cev rau lub ntsiab kev tshawb fawb kev taw qhia rau BIW txhuas daim ntaub ntawv.
2. Tuag-Cov ntaub ntawv pov thawj
2.1 Qhov tseem ceeb metallurgical tsis
Cov yam ntxwv tseem ceeb uas tswj cov kua- mus rau- kev hloov pauv hauv HPDC suav nrog cov kua dej kub, qhov kub thiab txias, lub sijhawm crystallisation thiab shrinkage.
- Liquidus yuav tsum tsawg li tsawg tau kom txo tau cov oxidation thiab cov roj khaws cia-.
- Lub sijhawm nqaim crystallisation (<50 °C) improves fluidity and reduces hot-cracking tendency.
- Shrinkage txiav txim siab hloov volumetric los ntawm cov kua rau khoom. Shrinkage yog inversely proportional rau Si cov ntsiab lus; ntawm ntau dua lossis sib npaug li 25% Si shrinkage zero. Tam sim no HPDC alloys nthuav tawm 0.5-0.6% shrinkage.
2.2 Thawj- tiam tshav kub- kho tau alloy: AlSi10MnMg
Tsim los ntawm Rheinfelden Alloys (Lub Tebchaws Yelemees), AlSi10MnMg yog kev ua haujlwm -nees rau nruab nrab- lub tshuab nqus tsev loj- pab HPDC qhov chaw xws li pem hauv ntej poob siab yees uas tsim los ntawm 3 500–{5}} t tshuab.
- Si ≈10 %: txhim khu fluidity, corrosion kuj thiab tuag- tso tus cwj pwm; khaws eutectic Si hauv qab qhov tseem ceeb uas cuam tshuam rau kev ua haujlwm.
- Mg: ntxiv dag zog ntawm Mg₂Si precipitates tom qab T6 / T7 kho cua sov; cov ntsiab lus yog capped kom txo qis kub tearing.
- Fe + Mn: Fe txhim kho kev tuag- tso tawm tab sis ua cov koob nkig; Mn hloov cov koob no kom tsis muaj teeb meem hauv Suav - cov ntawv theem, ua kom muaj siab -Mn / qis-Fe tsim.
- Cu & Zn: txwv rau qib kab kom tsis txhob muaj kev nplua thiab xeb.
- Ti & Sr: Ti refines nplej; Sr hloov Si morphology rau spheroids, tsa elongation.
Tom qab T7 temper, poob siab-ntauwd castings ua tiav YS Ntau dua lossis sib npaug rau 120 MPa, UTS Ntau dua lossis sib npaug rau 180 MPa thiab elongation Ntau dua lossis sib npaug li 10% - haum rau tus kheej- tho rivet (SPR) sib dhos. Txawm li cas los xij, kev kho cua sov ua rau muaj qhov tsis txaus ntseeg nyob rau hauv ib qho loj - daim castings, tsav txoj kev loj hlob thib ob - tiam tsis yog - tshav kub- kho cov alloys.
2.3 Thib ob- tiam tsis yog- cua sov- kho tau cov alloys
Cov no poob rau Al-Si thiab Al-Mg tsev neeg; Al-Mg muaj lub zog ntau dua tab sis muaj ntau yam khov thiab muaj zog kub -kev nyiam tawg, yog li Al-Si qib dominate.
- Castasil-37 (AlSi9MnMoZr): siab-Si variant nrog Mo & Zr rau siab- kub lub zog; ultra-low Mg (0.06%) zam lub hnub nyoog hardening.
- C611 (AlSi4-7Mg): Tesla's rear-floor alloy. Low Si improves elongation and cuts cost by omitting Mo/Zr. Mg (0.15–0.25 %) provides modest bake-hardening. The lower Si reduces fluidity, demanding larger draft angles (>3 degree). Kev ua haujlwm tsis ntev los no qhia tau hais tias ntxiv V refines eutectic Si thiab rov ua kom muaj dej ntws.
Lub hom phiaj cov khoom rau ib qho -daim castings yog YS Ntau dua lossis sib npaug rau 120 MPa, UTS Ntau dua lossis sib npaug rau 250 MPa thiab elongation Ntau dua lossis sib npaug rau 9.5 %- dhau ua ntej- tiam ua haujlwm yam tsis muaj kev kho cua sov. Tus nqi-tsav, qis-Si, tsis yog- tshav kub- kho tau Al-Si alloys yog li muaj qhov pom zoo tshaj plaws raws li kev loj hlob.
3. Lub tshuab nqus tsev siab-Txoj kev tuag-Casting txheej txheem
3.1 Txheej txheem ntws & kab layout
ib. Tuag-casting kob: nruab nrab ntawm 6 600 t (los yog loj) tshuab, suav nrog pwm- tswj kub thiab automated tuag- tshuaj tsuag neeg hlau. Ua ntej- kub tuag rau 150-230℃; 40-50 ywj siab dej / roj circuits tswj ± 10℃uniformity, saib xyuas los ntawm infrared sensors.
b. Dej quench: castings tawm qhov tuag ntawm ~ 300℃thiab submerged nyob rau hauv 20-30℃dej kom ceev ceev txias (sib npaug rau ceev-anneal), txhim kho txhua yam khoom.
c. De-gating: plasma txiav rau complex profiles; trimming tuag rau qhov chaw tiaj tus; nyob rau hauv - tuag khob- tawm rau xaiv overflows.
d. Straightening: txias los yog sov calibration presses raug distortion, tab sis zam thaum twg los tau.
e. Machining: 5-axis CNC laum qhov thiab mills high-precision nto; Lub sij hawm voj voog 3-5 s rau ib lub qhov, feem ntau cov kab tsis muaj dab tsi.
3.2 Tuag thiab gating tsim
- Gating philosophy: shock towers thiab longitudinal rails siv sab rooj vag; rear-cov plag tsev txais lub hauv paus rooj vag vim lub log -arch geometry (Z-}qhov siab 780 mm).
- Central rooj vag dav Ntau dua los yog sib npaug rau 420 mm kom zoo ib yam ntev; Cov dej ntws tawm thiab cov pa tawm tau muab tso rau ntawm qhov chaw deb tshaj plaws kom ntes cov hlau txias thiab oxides.
- Lub tshuab nqus tsev txuas mus rau kev sib cais - kab vents ua tiav<0.005 MPa cavity pressure. The vacuum valve closes <100 ms after metal reaches the gate, preventing metal ingress while exhaust plates continue venting to the end of fill.
3.3 Filling thiab solidification theem
Kauj Ruam 1 - Kev txhaj tshuaj qeeb (4-5 s): plunger nce qib ntawm qis ceev, kaw lub qhov rooj thiab tshem tawm cov cua nkag.
Theem 2 – Kev txhaj tshuaj sai (100–150 ms): hlau sau cov kab noj hniav ntawm 30–60 m / s rooj vag tshaj tawm.
Theem 3 - Kev siv zog: siab peaks tam sim ntawd; intensifier xa 60-90 MPa rau noj shrinkage.
Theem 4 - Tuav: 3-8 s nyob rau hauv lub siab zoo li qub thaum lub casting solidifies; 10-20 s nyob ua ntej ejection kom muaj zog txaus rau demoulding.
3.4 Cov txheej txheem tseem ceeb (rov qab- piv txwv hauv pem teb)
- Hlau kub: 670–690℃(tsawg kawg kom sau cov ntu siab).
- Tuag kub: 200 ± 20℃.
- Qhov ceev ceev: 35–50 m/s.
- Intensification siab: 75 MPa.
- Nqus:<5 kPa.
Qhov txiaj ntsig zoo tau raug kaw los ntawm kev sib txuas thawj zaug CFD nrog lub khw rov ua dua - hauv pem teb tuning.
3.5 Pwm-Flow insights
- Flow tracking: simulations xyuas cov laminar pem hauv ntej propagation thiab uniform cheb kab noj hniav, tiv thaiv txias shuts thiab oxide entrapment.
- Thermal mapping: temperature drop >30℃ntawm ladle thiab kawg - ntawm -fill chij pheej hmoo ntawm txias- ntws; cov roj cua sov hauv zos lossis qhov rooj qhib qhov rooj yuav tsum tau ua.
- Solidification: kawg-rau- khov tuab thaj tsam hais kom txias- channel tso; Lub rooj vag ua ntej lub qhov rooj khov yog zam los ntawm kev tuav lub rooj vag tuab Ntau dua lossis sib npaug li 3.5 hli.
- Gas thiab porosity: macro-siab<3 MPa and micro-gas content <2 µg are used as thresholds; deviations trigger redesign of vents or overflow volumes.
Cov cuab yeej CFD tam sim no ntseeg tau tias twv ua ntej sau thiab qhov tsis zoo tab sis tseem nyob hauv - kwv yees kev hloov pauv thiab qhov tseeb qhov tseeb ntawm qhov kawg - thaj chaw ntawm kev txhim kho nquag.
4. Cov ntsiab lus mob tam sim no
4.1 Mechanical khoom tsis txaus
Tsis yog-kub-kho cov castings yuav tsum ncav cuag YS Ntau dua lossis sib npaug rau 120 MPa, UTS Ntau dua lossis sib npaug rau 250 MPa, elongation Ntau dua lossis sib npaug li 9.5%. Nyob rau hauv kev xyaum, tej thaj chaw deb cheeb tsam ntawm complex qhov chaw (xws li, log-arch tops) poob luv luv: lub zog poob 10-20% thiab elongation yuav plunge mus rau 3%. Cov cheeb tsam no tau txais cov hlau txias, cov kab mob sib kis uas ua rau lub sijhawm kawg, harboring pores thiab oxides.
Kev txo qis: nruab nrab qhov rooj ntxiv rau cov phab ntsa xaiv - tuab txav siab - chaw thau khoom ze rau ntawm lub rooj vag. Yav tom ntej multi- rooj vag technologies los yog raws li lub valve gating yuav daws tau qhov teeb meem; rau tam sim no, cov khoom tsim yuav tsum khaws Z- qhov siab<500 mm and draft angles ≥15 ° where feasible.
In summary, driven by China's dual-carbon strategy and rapid vehicle electrification, lightweighting has evolved from an option to an imperative. Vacuum high-pressure die casting-thanks to its short process chain, near-net-shape capability, and high material utilization-has become the dominant route for large aluminium and magnesium body components. On the material side, second-generation low-silicon, non-heat-treatable Al-Si alloys now balance strength, ductility, and cost more effectively than ever. On the process side, the integration of >6 000 t tuag-casting Islands, siab- lub tshuab nqus tsev, 3-D conformal cooling, thiab tiag-lub sij hawm pwm- flow analysis tau hloov "cam khwb cia- hloov- ntawm-weld" cov ntsiab lus rau hauv kev muaj tiag. Txawm li cas los xij, cov cuab yeej poob- tawm hauv thaj chaw deb ntawm qhov chaw nyuaj, tuag lub neej, thiab qhov tseeb ntawm qhov seem tseem muaj cov kev sib tw uas xav tau kev sib koom ua ke-kev ua kom zoo ntawm cov khoom, khoom siv, cuab yeej, simulation, thiab khw- kev xyaum hauv pem teb. Saib tom ntej, kev loj hlob ntawm ntau- rooj vag dynamic tswj, AI-raws li nyob rau hauv- kab kev soj ntsuam zoo, thiab qis- carbon recycled Al-Mg alloys yog teem rau txuas lub tshuab nqus tsev HPDC los ntawm pem hauv ntej pem teb mus rau tag nrho lub cev-nyob rau hauv{{21} lub kaum sab xis ntawm lub xyoo tom ntej no ntawm kev tsim khoom hnyav rau cov tsheb tshiab-zog.
