Integrated tuag-casting tau dav siv nyob rau hauv kev lag luam tsheb thiab yog overturning tsoos tsheb manufacturing. Daim ntawv no sau thiab txheeb xyuas cov ntsiab lus tseem ceeb ntawm theem tam sim no- tuag- casting alloys, khoom siv, tuag tsim, post-kev ua thiab tshuaj xyuas- qhia txog cov teeb meem tshwm sim thaum lub sij hawm casting, lawv lub hauv paus ua rau thiab kev tiv thaiv kev ntsuas, thiab thaum kawg nthuav tawm qhov kev xav txog kev siv tshuab.
Tsav los ntawm Tuam Tshoj txoj cai "dual-carbon" txoj cai thiab thev naus laus zis Roadmap 2.0 rau Zog-Txuag thiab Tshiab- Lub Tsheb Hluav Taws Xob, lub khw NEV hauv tsev tau loj hlob sai, nrog kev muag khoom pheej yig dua cov ntaub ntawv siab. Ntawm tag nrho cov kev hloov kho tshiab, kev sib tw - dua li lub zog - tsheb ciav hlau lossis kev txhim kho tsav tsheb - muab txoj hauv kev zoo tshaj plaws los txo qis kev siv hluav taws xob thiab emissions. Lightweighting feem ntau yog tackled los ntawm peb lub ces kaum: sib dua cov ntaub ntawv, cov qauv optimization thiab advanced manufacturing txheej txheem. Xyoo 2019 Tesla tau siv loj- nplai sib xyaw ua ke tuag- nrum rau tus qauv Y, hloov lub rooj sib txoos ntawm ntau dua 70 stamped-thiab-welded qhov chaw thiab pioneering "los ntawm- xoom- mus- tag nrho kev lag luam. Kev sib xyaw ua ke ntawm cov alloys sib sib zog nqus thiab ib qho -steev tuag-casting ruaj cov khoom ua tau zoo thiab lub zog thaum txhawb kev tsim khoom thiab txo cov khoom pov tseg.
1. Cov khoom siv rau kev sib xyaw tuag- Casting
Automotive structural qhov chaw uas tsim los ntawm kev sib xyaw casting thov puas tau- kev ua tau zoo dua, ua tsis yog - cua sov- kho tau, siab - ductility lub teeb alloys tsom ntawm R & D. Kev loj hlob vam khom rau CALPHAD-raws li kev suav thiab siab- dhau los ntawm kev sim. Kev ua kom nrawm nrawm, micro-alloying thiab microstructure tailoring yog ua haujlwm los txhim kho tag nrho cov khoom. Table 1 qhia tau hais tias Al-Si, Al-Mg thiab Mg-Al systems yog cov kev kawm dav tshaj plaws hauv kev lag luam. Tsis yog-kub- kho tau Al alloys muaj cov txheej txheem tsawg dua, tus nqi qis dua thiab qis CO₂ emissions, nyiam lub ntiaj teb kev nyiam.
1.1 Tsis yog- cua sov- kho tau Al alloys
Cov khoom tseem ceeb ntawm casting- melting point, fluidity, shrinkage thiab kub-tearing resistance- yuav tsum sib npaug.
- Al-Si system: Si improves fluidity, reduces shrinkage and hot-tearing, and modestly raises strength. Depending on Si content, alloys are classified as hypo-eutectic (4–9 % Si), eutectic (10–13 %) or hyper-eutectic (14–22 %). Coarse eutectic structures are refined by Cu, Mg, Mn, etc. Examples: Alcoa's C611 (>12% elongation ntawm qis Si) thiab Magna's Aural5 (Ntau dua lossis sib npaug rau 11% elongation). Suav kev kawm tau tsim THAS thiab JDA series alloys tam sim no tau txais los ntawm OEMs loj.
- Al-Mg system: Mg (2–12%) txhim khu fluidity, machinability, zog thiab corrosion kuj ntawm spinel nto zaj duab xis. Muaj peev xwm -Al₃Mg₂ rhiab heev ntawm 50–200℃yog mitigated los ntawm nplua nplej tau nyob rau hauv uas tsis yog - tshav kub- txoj kev kho.
- Micro- alloying:<1 % additions of Fe, Mn, Sr, Ti, Cr, RE, etc. provide second-phase strengthening (see Table 2).
1.2 Mg alloys
Mg alloys yog ~ 33% sib zog dua Al thiab 75% sib zog dua hlau, tab sis lawv cov Young's modulus yog 20 × ntawm cov khoom siv polymer. Fluidity zoo heev thiab tsawg tuag-adhesion ua rau lawv zoo tagnrho rau siab-siab tuag-casting (HPDC). Porsche, Ford thiab Mercedes twb ntiav Mg cov khoom siv. Hauv tsev, Chongqing University tau sim- tsim ib qho loj -daim Mg castings- tsis muaj cov ntaub ntawv zoo sib xws nyob txawv teb chaws.
- Mg-Al-based non-heat-treatable alloys: Traditional HPDC alloys include AZ91D (medium-temp, high strength), AM50A/AM60B (high ductility) and AE44 (elevated-temperature). Sn >0.3% txhim kho castability thiab txo cov tuag- nplaum; Zn boosts elongation. Ib qho tshiab Mg-Al-Zn-Mn HPDC system muaj zog tunable. RE (La+Ce, Nd, Gd) thiab Ca txhim khu kev ua haujlwm siab - kub.
- Cov tshuab tshiab: MRI240D / 250D / 260D (Mg-Zn-Zr-RE) xa cov ductility thiab flowability. Mg-RE-Al HPDC alloys (5 % RE, 0.5 % Al) khaws lub zog thiab ductility ntawm 250℃.
2. Tuag -Casting Equipment & Process
Integrated tuag-casting yog npaj raws li "tuag-casting kob" integrating melting, casting, spraying, cooling, defect detection, laser marking, degating and straightening. Cov cuab yeej ntog rau hauv melting, casting thiab post-processing units.
2.1 Melting unit
Al ingots yog melted ntawm 700-710℃nyob rau hauv inert{2}}gas stirring kom tshem tawm inclusions. Lub qhov cub dosing ces muab qhov hnyav / qhov kub thiab txias.
2.2 Casting Unit
- Die-casting machine: Cold-chamber machines are standard. Part size is >3 × pa castings, phab ntsa thickness 3-5 hli, hauv zos<2.5 mm, requiring clamping force ≥60 MN. Global suppliers: Buhler, Idra, Italpresse, LK, Yizumi, Haitian. Direct-pressure clamping replaces three-plate toggles; advanced hydraulics ensure uniform filling.
- Txheej txheem: tshuaj tsuag → kaw → ladle → txhaj → intensify → qhib. Micro- tshuaj tsuag los yog electrostatic tsuag nrog zoo li lub nozzles kom meej meej tso tawm - tus neeg saib xyuas zaj duab xis. High- nqus tsev vacuum (<5 kPa) suppresses air entrapment and porosity. Injection speed/pressure and die temperature are optimized via die-thermal sensors and conformal cooling to achieve directional solidification.
2.3 Post-chaw ua haujlwm
Degating, trimming, straightening thiab tshuaj xyuas (pom, xiav-teeb, X-ray) lav qhov tseeb qhov tseeb thiab qhov tsis xws luag -dawb qhov chaw.
3. Tuag -Casting Dies
Cov tuag suav nrog kev ruaj khov thiab txav ib nrab nrog cov kab noj hniav, cov neeg khiav dej num, cov dej ntws tawm, qhov cua thiab cov thav ntawv.
3.1 Cov khoom siv tuag
H13, 3Cr2W8V, Y10, HM1 steels raug xaiv rau cov thermal expansion, siab kub zog, qaug zog thiab yaig kuj. Cr, Mn, V, Mo, W yog alloyed rau tailor khoom.
3.2 Kev tswj qhov kub thiab txias
Cov chaw kub kub nyob ze ntawm lub rooj vag thiab thaj chaw txias ntawm qhov kawg ntawm qhov kawg yog sib npaug los ntawm cov cua txias raws li kev sib tw, cov duab infrared thiab hauv - pwm sensors.
3.3 Nqus tswj
Loj nyias qhov xav tau<5 kPa cavity pressure; multi-cylinder hydraulic vacuum valves must close rapidly to avoid metal ingress and cycle interruptions.
3.4 Pwm-flow tsom xam
Software kwv yees sau, solidification thiab tsis xws luag, ua kom parameter optimization ua ntej txiav steel.
4. Kev soj ntsuam tsis raug
4.1 Cov cua txias kaw (cov cim ntws)
Pom zoo li folds los yog txheej uas ob lub hlau pem hauv ntej ntsib ntawm qhov kub thiab txias / tshaj tawm. Ua rau: qis yaj / pwm kub, txhaj tshuaj qeeb, tsim lub rooj vag tsis zoo, roj nkag. Cov kev kho mob: nce melt temp, optimize khiav / rooj vag, xyuas kom qhov cua, siv simulation los xyuas qhov ntws fronts.
4.2 Shrinkage porosity
Cov voids tsis tu ncua nyob rau hauv tuab seem vim tsis txaus noj thaum lub sij hawm solidification. Ua rau: cais cov kub kub, lub qhov rooj thaum ntxov khov, tsis tshua muaj zog siab, siab tuag / yaj kub, nyias biscuit. Cov kev daws teeb meem: lub tshuab nqus tsev pab, tsim qauv pub, tuag- tswj qhov kub thiab txias, simulation- coj riser / khiav optimization.
4.3 Tuag soldering
Al alloy adheres rau tuag nto, tshwj xeeb tshaj yog nyob rau hauv siab tuag kub. Ua rau: tsis zoo cov cua ntsawj ntshab, ntxhib nto, tsis txaus tso tawm tus neeg sawv cev, qis Fe hauv alloy, siab rooj vag tshaj tawm. Cov kev daws teeb meem: tsim nyog tso tawm- tus neeg saib xyuas ntau npaum li cas, ua kom txias txias, tsim nyog cov khoom siv hluav taws xob, cov kaum sab xis siab dua lossis sib npaug li 1.5℃.
4.4 Kev hloov pauv
bowing, twisting los yog warpage. Ua rau: sib txawv shrinkage, tsis sib luag phab ntsa thickness, ejection stress, quenching. Cov kev daws teeb meem: tsis yog- cua sov- kho tau cov alloys, cov phab ntsa tuab tuab, optimized gating/venting, tswj cov txheej txheem tsis, nyob rau hauv - tuag straightening los yog post straightening fixtures.
5. Cov lus xaus
Txij li Tesla's Model Y, OEMs thoob ntiaj teb-Volvo, Mercedes-Benz, VW, Toyota, GM, Hyundai, NIO, XPeng, Geely, Changan, Dongfeng- tau txais kev sib koom ua ke tuag-casting rau ntau- qauv platforms. Lub tshuab ua rau ib feem - suav txo, kev sib koom ua haujlwm ua haujlwm thiab ua haujlwm tau zoo ntawm lub teeb yuag, siab - lub zog, cov khoom muaj tseeb. Cov teeb meem tseem ceeb suav nrog kev tswj tsis raug, alloy- txhim kho vaj tse thiab tuag{10}} lub neej txuas ntxiv, txhua qhov xav tau ntau dua automation thiab digitalization. Nrog kev nce qib tsis tu ncua hauv cov khoom siv thiab kev tsim khoom ntse, kev sib koom ua ke tuag-casting yog npaj rau kev siv dav dua hauv high{13}}kev tsim khoom kawg.
