The Quality of Automotive Aluminum Alloy Die Casting Parts (Part One)

Abstract: With the continuous development of the economy, science and technology, and the continuous improvement of people's living standards, higher requirements are put forward for the quality and practicability of automobiles. To ensure good performance, practical applicability, and to improve the design process and quality of the automobiles, comprehensive diagnosis and control of the quality of aluminum alloy die castings of automobiles were conducted to provide effective materials for automobile manufacturers and designers, and to promote the development of the automobile manufacturing industry.
 
The disadvantages of automobile aluminum alloy die casting were analyzed and studied, and the following disadvantages and defects were found. For the automobile aluminum alloy die casting parts, the automobile cylinder part is relatively large, especially the position of the head cover of the cylinder block, and the structure is more complicated. There were some holes in the cylinder surface and are not allowed for some parts, which will seriously affect the quality of die castings. Externally purchased components and materials, operational drawbacks also have an impact on the quality of automotive die castings. In order to improve the quality of automobile die casting parts, it is necessary to pay more attention to the above drawbacks, and to improve the process design links and the holes.
 
1. Comprehensive diagnosis of the quality of automotive aluminum alloy die castings
1.1 Diagnosing
For the automobile aluminum alloy die casting as a whole, the automobile cylinder part is relatively large, especially the position of the head cover of the cylinder block occupies a large space, and the structure is relatively cumbersome. Some parts of processed links and cylinder surfaces must not have holes. For those cylinder surfaces with holes, the distribution of holes is more diffuse, and there are strict specifications and requirements for the size. For the cylinder head, the camshaft position is accompanied by flaw detection. After processing, the size of the hole must meet the requirement of monitoring and the minimum standards. This kind of component brings great difficulty to design and manufacturing, and seriously affects the design and production efficiency. The die casting's technology and process cannot fully take into account the different links and parts of the entire die casting part, and the reconciliation between the production link and the process design link is bad. Some pore walls are accompanied by smooth features, and the depth of the pore walls is great, which are accompanied by gas holes. There are also some disadvantages such as holes that associate gas holes with shrinkage holes.
 
1.2 Comprehensive process diagnosis and analysis and image simulation analysis
Externally purchased components and materials, operational drawbacks, process design links and practical applicability of mechanical devices all have a great impact on the safety of automobile die casting parts, resulting in changes in quality, and the scrapping of castings in severe cases. All of the above factors have the characteristics of variability, which will have a great impact on the quality of the castings. Changes in any link will cause fluctuations in the quality of the castings. For the changes in the quality of casting caused by externally purchased components and materials, operational drawbacks, process design mitigation, practical applicability of mechanical devices, it is not easy to find the main reasons for the impact.
 
Faced with this situation, it is necessary to increase the continuous tracking and investigation of the die casting's design and process links. It is necessary to observe and analyze the production dates for different die castings, establish a rational timing arrangement, the quality-oriented goal of castings, and monitor and continuously observe the following links, including comprehensive monitoring and tracking of raw materials, auxiliary materials, smelting links, design and process production parameters of castings, and monitoring quality of castings. For the image simulation analysis, the main defect of the die casting part is reflected in the gear chamber. The main factors affecting this defect are the influence of gas changes and shrinkage, which bring great defects to the holes. For castings, the gas is mainly obtained from the inside of the solution and the release agent. The gas generated in the solution is closely related to the types and properties of materials, and the smelting technology of the die casting part.