[China Aluminum Network] Japan's casting technology was formed after the Second World War in a new form of recovery. Afterwards, through the introduction of new technologies from Europe and the United States, it has gradually developed. This article mainly introduces two new aluminum alloy die casting casting technologies in Japan.
A, semi-solid forming aluminum alloy manufacturing technology
Traditional aluminum alloy die castings have poor reliability in terms of mechanical properties and pressure resistance. Therefore, a high-quality forming method, the semi-solid forming method, attracts attention. The main point of this method is to manufacture castings with liquid metal, solid metal and mixed state (semi-melting), which can greatly reduce the internal defects of the casting, thereby improving the pressure resistance and mechanical properties. This method uses blanks made by special methods such as electromagnetic stirring. At present, the blanks used by Japanese manufacturing plants are imported from abroad, and there are problems in terms of production costs, stable supply, and recycling of surplus materials.
The manufacturing technology of blanks researched and developed on its own is based on the processing strain introduction method, and has been improved through a number of research and trials to establish a technique for producing a uniform spherical body with initial generation of approximately 100 μm under semi-molten heating conditions. The main points are:
1 is to suppress the growth of primary uniform spheroids in the prepared blank, control the solidification rate, and determine the chemical composition.
2 control the introduction of the speed and temperature when processing strain;
3 Equilibrium introduction technology for processing strain.
The semi-solid forming blank produced by this method has uniform microstructure after heat treatment at the semi-melting temperature. Hubs made from several blanks have a finer microscopic structure at both the top and the thin wall compared to the original product. Excellent mechanical properties, fully meet the requirements of rotary bending test technical standards.
Second, fiber-reinforced engine block
The automotive engine needs to be lightweight, compact, and high-performance. Light weight is mainly due to the use of aluminum alloy in the cylinder of the engine. The compactness mainly reduces the size of the cylinder bores in the cylinder, so as to shorten the overall length of the cylinder. The high output is that the same cylinder body expands the bore diameter to increase the exhaust gas volume, which is compatible with the simplification. High performance is to make the cylinder aluminum alloy as a whole, so that the cylinder hole heat conduction is good, deformation is small, thereby improving engine efficiency and saving energy.
The original cylinders were mostly made of aluminum alloy die-casting and cast-in cast iron cylinder liners, which could not meet the above requirements. As a result, an overall aluminum alloy engine block was developed, and the bore portion was made of fiber-reinforced metal.
The part of the cylinder bore is made of a ceramic fiber preform, and the gap is immersed in an aluminum alloy liquid and replaced with air. The preforms are positioned in the press pattern and are the same cast iron bushings used in the past. The preform is preheated, fixed on a support, and the support is positioned in the profile.
In addition, laminar die casting is used to make the fiber gap of the preform easily immersed in the aluminum liquid. In order to prevent the temperature of the aluminum liquid from being lowered, a powdery lubricant is applied to the injection chamber and a powdery release agent is applied to the pressure type. After casting, the support can be recycled for repeated use.
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