ã€China Aluminum Network】When designing the structure of aluminum and magnesium alloy castings, several key considerations should be taken into account to ensure optimal performance and manufacturability. First, due to their relatively low melting points, both aluminum and magnesium alloys can be produced using various casting techniques. Therefore, it is essential to consider the specific casting method during the design phase to ensure that the geometry supports the process effectively.
Second, these materials are best suited for thin-walled structures with uniform thickness to prevent shrinkage defects and improve mechanical strength. If wall thickness varies, feeding systems or localized thickening can be used to promote proper solidification and reduce porosity.
Third, aluminum and magnesium alloys are highly susceptible to oxidation and gas absorption, which can lead to porosity and reduced mechanical properties. To minimize this, avoid large horizontal surfaces and ensure smooth transitions in the casting design to prevent turbulence during metal flow.
Fourth, for castings requiring airtightness, care must be taken to avoid core supports that do not fuse properly with the casting body, as this can cause leaks. Additionally, because these alloys have higher thermal contraction and lower elastic modulus, they are more prone to distortion and cracking. This makes structural design critical to reduce stress concentration.
Some key design strategies include: using I-shaped, slotted, or box-shaped cross-sections to increase stiffness; ensuring reinforcing ribs are appropriately sized to avoid stress concentration; reinforcing edges around holes with flanges; and using ribs in wheel castings to strengthen connections between hub and web. Thin-walled parts can benefit from ribs or stepped sections, while bolt placement should be optimized to avoid excessive local stress. Instead of using large-diameter bolts spaced far apart, smaller ones are preferred to distribute forces evenly and prevent deformation. Using washers and larger nuts can also help reduce pressure on bosses.
For thin-walled shell-like components, avoid abrupt shapes to prevent stress concentrations. Since these alloys have limited elasticity, press-fit designs must account for deformation and disassembly requirements. Threaded holes should be longer than those in cast iron or steel—typically L/d = 2 for aluminum and 2.5 for magnesium.
Magnesium alloys have higher compressive strength than tensile strength, so asymmetric cross-sections should be considered in design to maximize load-bearing capacity. Also, magnesium alloys are prone to corrosion, so surface treatments are commonly applied. Structural design should avoid water-trapping pockets and sharp corners to maintain protective coatings.
Finally, bimetal casting and insert casting techniques can be useful in solving complex structural challenges in aluminum and magnesium alloy castings. By carefully considering these factors, engineers can create more reliable and efficient casting designs.
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