Study On The Tilt-casting Process Of Magnesium Alloy Air Intake Manifold

The magnesium alloy, is the best and the lightest metal structural material,is honored as"the 21st century's green structural material". China is rich in magnesium resources, however, there has great gap between Chinese and other developed countries, such as Europe, the United States in magnesium alloy research and application. Therefore, using our advantages in resources, changes in technology, economic advantages and enhance international competitiveness is our urgent task.The author uses South Korea's AnyCasting casting simulation software for the tilt-casting magnesium alloy air intake manifold of simulation technology to optimize and detailed study on magnesium alloy casting process. By selecting four factors, such as pouring preheat temperature, mould preheat temperature, tilt velocity, sprue cup preheat temperature to carry out orthogonality experiment design. Through the simulation test, draws following conclusion: (1) Obtaining a group of optimum technological parameters, namely, tilt velocity is 2.71r/min, upper mould preheated temperature is 450℃, lower mould preheated temperature is 550℃, molten metal temperature is 750℃, sprue cup preheated temperature is 550℃, the formation result simulation is good. (2)According to orthogonality experimental design, it may be sure that mould preheated temperature is greater impacting on the simulation results, takes second place, are molten metal preheated temperature, tilt velocity, sprue cup preheat temperature. (3)By changing runner mode of entry, the molten metal fluid from air intake manifold's big end, the molten melt flows steadily, tend to order solidification, the formation result simulation is more well.In the optimal parameters,simulation of aluminum alloy air intake manifold, comparing the characteristics of the two alloys, draws the following conclusion: (1) The aluminum alloy starts the time which solidification to be late; contrarily, to magnesium alloy. When the aluminum alloy filling arrives 95%, it has not started to solidification, but the magnesium alloy solidification already arrived at 16.1%. (2) Temperature from pouring temperature(750℃)down to their respective alloy solid temperature, magnesium alloy's cooling time is longer than the aluminum alloy's. Magnesium alloy cooling time is 1950s, Aluminum alloy cooling time is 1149s. (3) From fifth test point analysis, when the molten metal filling just arrived at the blind feeder, magnesium alloy melting temperature is only 600℃, but its'liquidus temperature is 596℃, the solidus temperature is 468℃, it prove that it approach to crystallization, the temperature gradually reduces,solid-liquid coexistence, it is prone to pouring as well as feeding. Solidification from bottom to top, the blind feeder's function is small, molten aluminum temperature as high as 700℃, but its'liquidus temperature is 615℃, the solidus temperature is 520℃, completely in the liquid state, the blind feeder's function is good. (4) Through theoretical calculation, during the entire filling process, the velocity of aluminum alloy and magnesium alloy is lower than Re, completely in laminar flow. (5) Calculates according to the alloys'physical parameter, between pouring temperature(750℃) to respective alloy liquidus, heat release of specific volume of magnesium alloy is 1.1times than that of aluminum alloy, in solidification process of reducing every1℃specific volume's aluminum alloy release's heat is about magnesium alloy's 1.8 times. During the filling and solidification process, specific volume's aluminum alloy release's heat is about magnesium alloy's 1.21 times.