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Jiang K.-Y.,Tongji University | Xiao T.-Y.,Tongji University | Sun J.,Suzhou Sanji Foundry Equipment Co.
Tezhong Zhuzao Ji Youse Hejin/Special Casting and Nonferrous Alloys | Year: 2013

The microstructure and properties of squeezing casting ZL111 aluminum matrix composites with 20% silicon carbide particles by horizontal squeezing casting machine were investigated. The results show that the composites can be prepared by horizontal squeezing casting with specific pressure of 135 MPa and extrusion punches speed of 0.4 m/s as well as pouring temperature of 710°C. The silicon carbide particles are uniformly distributed in the microstructure, and absence of aggregation of the SiCp can be observed, so the SiCp content is uniform in the composites samples. In addition, the SiC particles are distributed only in the eutectic structure in the composites samples. Wear resistance of the composite samples is significantly improved, leading to a sharp wear of cutting tool. Meanwhile, the Brinell hardness is in range of 76.7 HB~94.4 HB, which is basically near to that of ZL111 alloy.


Guan R.G.,Northeastern University China | Guan R.G.,Lanzhou University of Technology | Zhao Z.Y.,Northeastern University China | Li Y.D.,Lanzhou University of Technology | And 3 more authors.
Journal of Materials Processing Technology | Year: 2016

The microstructures of A356 alloy parts contained near-round or rosette α-Al grains and eutectics at grain boundaries. Melt processing by vibrating slope could refine grain size and eliminate eutectic phase segregation as well as regional segregation which usually occurred in traditional squeeze casting. Average grain diameter of α-Al grain increased from 44 μm to 64 μm, and grain average roundness decreased firstly from 2.9 to 1.7 then increased to 3.3 with the increase of casting temperature. At casting temperature from 670 °C to 680 °C, crack and cooling shut usually occurred in the products due to poor flow ability of the alloy. When the casting temperature was 690 °C, the alloy had a good filling ability and smooth product with fine near-round or rosette α-Al grains and homogenous eutectics has been obtained. The ultimate tensile strength and elongation of semisolid squeeze casting A356 alloy reached 232 MPa and 7%, which were improved by 12% and 21% respectively as comparing with that of traditional squeeze casting. © 2015 Elsevier B.V. All rights reserved.


Yang Q.,Jiangsu University | Dai Y.,Jiangsu University | Jiang Y.,Jiangsu University | Xu R.,Jiangsu University | And 2 more authors.
Tezhong Zhuzao Ji Youse Hejin/Special Casting and Nonferrous Alloys | Year: 2015

The A356 alloy automotive sub-frame was produced by indirect squeeze casting. The process scheme and the process parameters of indirect squeeze casting were determined. The sub-frame was manufactured successfully by the advanced 2000T vertical squeeze casting machine. The microstructures and mechanical properties of the sub-frame have been investigated by tensile testing, optical microscope and scanning electronic microscope. The results reveal that the sub-frame castings exhibit the satisfied appearance with compact internal structure and absence of casting defects with the pouring temperature at 690-710℃, the casting pressure at 95 MPa, the mold temperature at 240℃ and the holding time of 20 s. The tensile strength, elongation and hardness of aluminum alloy sub-frame specimen after T6 heat treatment can reach to 291 MPa, 9.2% and 96 HBW, respectively. With the bench test, the require-ments of fatigue property can be satisfied and the lightweight level of vehicle is improved. ©, 2015, Journal Office of Special Casting and Nonferrous Alloys. All right reserved.


Sun J.,Suzhou Sanji Foundry Equipment Co. | Xu S.-X.,Suzhou Sanji Foundry Equipment Co. | Tang J.,Tsinghua University | Wang F.-F.,Tsinghua University | Han Z.-Q.,Tsinghua University
Zhuzao/Foundry | Year: 2015

With the demand for lightweight in automobile manufacturing, a squeeze casting process for an aluminum subframe component was designed, and numerical simulation technique was used to optimize the casting process. The subframe component was produced with a vertical squeeze casting machine SCV-2500. The results show that shrinkage defects were significantly reduced with the optimized process obtained by using numerical simulation. The as-cast microstructure is uniform, and after T6 heat treatment, the tensile strength is 280 MPa, the yield strength is 225 MPa, the elongation reaches 8.1%, and the hardness is HB 95. ©, 2015, Chinese Mechanical Engineering Society. All right reserved.


Tang J.,Tsinghua University | Han Z.,Tsinghua University | Wang F.,Tsinghua University | Sun J.,Suzhou Sanji Foundry Equipment Co. | Xu S.,Suzhou Sanji Foundry Equipment Co.
TMS Annual Meeting | Year: 2015

A coupled thermo-mechanical simulation method for three-dimensional squeeze casting components has been developed. The simulation was achieved by using ANSYS Parametric Design Language (APDL). The effect of volume shrinkage due to cooling and solidification, the effect of pressure on the latent heat release, the mutual dependence of interfacial heat transfer and casting deformation, and materials behavior under elevated temperatures were taken into account in the simulation. A step-shaped trial casting was simulated, which demonstrates the ability of the method to simulate the pressure transmission and decline inside the casting as well as the distribution and evolution of the interfacial heat transfer coefficient. Finally, the method was applied to simulate the solidification of an automotive sub-frame component, based on which the squeeze casting process of the component was optimized.


Yang Q.,Jiangsu University | Jiang Y.,Jiangsu University | Dai Y.,Jiangsu University | Xu R.,Jiangsu University | And 2 more authors.
Tezhong Zhuzao Ji Youse Hejin/Special Casting and Nonferrous Alloys | Year: 2016

The A356 alloy automotive sub-frame was produced by indirect squeeze casting. The process scheme and the processing parameters of indirect squeeze casting were determined. The sub-frame was manufactured successfully with the advanced 2000T vertical squeeze casting machine. The microstructure and mechanical properties of the sub-frame have been investigated by tensile testing, optical micro-scope and scanning electronic microscope. The results reveal that the sub-frame castings exhibit the satisfied appearance with compact structure and absence of casting defects with the pouring temperature of 690-710℃, the casting pressure of 95 MPa, the mold temperature of 240℃ and the holding time of 20 s. The tensile strength, elongation and hardness of aluminum alloy sub-frame specimen after T6 heat treatment can reach 291 MPa, 9.2% and 96HBW, respectively. With the bench test, the requirements of fatigue property can be satisfied and the lightweight level of vehicle is improved. © 2016, Journal Office of Special Casting and Nonferrous Alloys. All right reserved.


Zhang Q.,Xi'an Jiaotong University | Cao M.,Xi'an Jiaotong University | Zhang D.,Xi'an Jiaotong University | Zhang S.,Xi'an Jiaotong University | Sun J.,Suzhou Sanji Foundry Equipment Co.
Advances in Mechanical Engineering | Year: 2014

Integrated casting and forging process (ICFP) is a new manufacturing method combining the advantages of both casting and forging. Aluminum structure parts, such as aluminum alloy automobile wheel, with complex shape and excellent mechanical properties can be produced by this process. The effects of different process parameters on the ICFP of the automobile wheel were simulated by Forge software. Microstructure of forging region and the nonforging region were studied by experiment. The results show that die temperature, static pressure of the injection piston, forging speed, and material flow have significant influences on the process. Compared with nonforging region, the microstructure of forging region becomes finer, more uniform, and denser. Meanwhile, the casting defects can be removed and mechanical properties improved. © 2014 Qi Zhang et al.


Wu G.Y.,Nanjing Southeast University | Tang W.C.,Nanjing Southeast University | Wan S.P.,Suzhou Sanji Foundry Equipment CO
Applied Mechanics and Materials | Year: 2014

The research object of this paper is double-toggle clamping mechanism of DC3500 die casting. The theoretical formulas of stroke ratio and force amplification are proposed and the prototype model is established in ADAMS to generate kinematic and mechanical curves. Moreover, experimental values are used to verify the validity of the theoretical formulas and simulation model, and the causes of experimental error are gaven. Thus, the theoretical model can be adopted directly for the design of larger double-toggle clamping mechanism to simplify the design cycle. © (2014) Trans Tech Publications, Switzerland.


Li X.,Jiangsu University | Wang J.,Jiangsu University | Sun J.,Suzhou Sanji Foundry Equipment Co. | Cheng K.,Guangdong Tayo Motorcycle Technology Co.
Tezhong Zhuzao Ji Youse Hejin/Special Casting and Nonferrous Alloys | Year: 2016

The indirect squeeze casting process and working principle of mold were determined based on analysis of the structure of gearbox and forming technology. During the stage of trial-mold, cold sandwich and shrinkage porosity were observed in gearbox produced by vertical squeeze casting machine SCV2000. After optimization of squeeze gearbox mold design, the defects such as cold sandwich and shrinkage porosity near sprue can be eliminated by optimizing structure of sprue bush and adding local pressurization core. Then the microstructures and mechanical properties of gearbox have been investigated. The results reveal that tensile strength, elongation and hardness of gearbox reach up to 317 MPa, 6.1%, 99HBS, respectively, meeting the use requirement. The X-ray flaw detection shows that the aluminum alloy gearbox exhibits satisfy surface quality with absence of shrinkage porosity and cavity, gas hole. © 2016, Journal Office of Special Casting and Nonferrous Alloys. All right reserved.


Tang J.,Tsinghua University | Wang F.,Tsinghua University | Han Z.,Tsinghua University | Sun J.,Suzhou Sanji Foundry Equipment Co. | Xu S.,Suzhou Sanji Foundry Equipment Co.
Tezhong Zhuzao Ji Youse Hejin/Special Casting and Nonferrous Alloys | Year: 2015

A coupled thermo-mechanical simulation of three-dimensional squeeze casting components has been conducted by using ANSYS software according to the basic principle and characteristics of the squeezing casting. Some factors influencing simulation were taken into account, such as effect of volume shrinkage due to cooling and solidification, the mechanical behavior of materials under evaluated temperatures, the characteristics of latent heat release, and the mutual dependence of interfacial heat transfer and casting deformation in the simulation. A step-shaped trial-part was simulated, which demonstrated the ability of the method to simulate the pressure transmit and fading inside the castings. Finally, the method was applied to simulate the solidification of an automotive subframe component, and the squeeze casting process of the component was optimized based on the simulated results. ©, 2015, Journal Office of Special Casting and Nonferrous Alloys. All right reserved.

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