Progress in Integrated Die Casting of Aluminum Alloys
TAN Yunxiang1, MA Juhuai1, ZHAO Haidong2, 3, XU Qingyan1
1. Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China;
2. South China University of Technology, Guangzhou 510640, China;
3. National Engineering Research Center of Near-Net-Shape for Metallic Materials, Guangzhou 510640, China
Aluminum alloys, known for their low density and high specific strength, are widely used in aerospace and a utomotive lightweight applications. Integrated die casting enables the production of large, complex, thin-walled castings, effectively aiding in weight reduction and range extension for aircraft and automobiles. This paper provides a comprehensive review of the development of large integrated die casting for aluminum alloys. It analyzes the compositional design of non-heat-treatment aluminum alloys and highlights the characteristics of the developed alloys. Additionally, it introduces the progress of domestic and international development of large integrated die casting machines and molds. The current state of numerical simulation research is summarized regarding mold filling, solidification, defects prediction, microstructure, thermal stress, and fatigue life prediction of integrated die casting parts. The paper concludes with a discussion of future developments in integrated die casting technology.