镁合金一体化压铸缺陷控制

doi:10.11900/0412.1961.2024.00310

金属学报

2025, Vol. 61

Issue (3): 383-396 DOI: 10.11900/0412.1961.2024.00310

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镁合金一体化压铸缺陷控制

蒋斌, 张昂(

), 宋江凤, 黎田, 游国强, 郑江, 潘复生

重庆大学材料科学与工程学院国家镁合金材料工程技术研究中心高端装备铸造技术全国重点实验室重庆 400044

Defect Control of Magnesium Alloy Gigacastings

JIANG Bin, ZHANG Ang(

), SONG Jiangfeng, LI Tian, YOU Guoqiang, ZHENG Jiang, PAN Fusheng

National Key Laboratory of Advanced Casting Technologies, National Engineering Research Center for Magnesium Alloys, College of Materials Science and Engineering, Chongqing University, Chongqing 400044, China

引用本文:

蒋斌, 张昂, 宋江凤, 黎田, 游国强, 郑江, 潘复生. 镁合金一体化压铸缺陷控制[J]. 金属学报, 2025, 61(3): 383-396.
Bin JIANG, Ang ZHANG, Jiangfeng SONG, Tian LI, Guoqiang YOU, Jiang ZHENG, Fusheng PAN. Defect Control of Magnesium Alloy Gigacastings[J]. Acta Metall Sin, 2025, 61(3): 383-396.

全文: PDF(2238 KB) HTML

摘要:

镁合金一体化压铸技术在汽车轻量化方面潜力巨大。但由于镁合金具有活泼的化学性质和较高的热裂倾向，以及一体化压铸件尺寸大、壁厚薄、几何形状更加复杂，成形过程中容易出现孔洞、热裂等各种缺陷，极大地影响了一体化压铸件的性能。本工作在简述压铸镁合金缺陷形成原因及孔洞、缺陷带和热裂3种典型缺陷防治措施的基础上，围绕熔体处理、合金开发、工艺优化和结构设计等方面，概述了镁合金一体化压铸缺陷控制方面的进展和挑战，为高性能镁合金一体化压铸缺陷控制提供了思路和方向。

关键词 ：镁合金, 一体化压铸, 缺陷, 微观组织, 工艺

Abstract：

The demand for lightweighting is rapidly increasing to meet the carbon peak and neutrality goals. Gigacasting integrates stamping and welding processes into a single high-pressure die-casting operation, streamlining production workflows and considerably enhancing production efficiency, thereby accelerating advancements in automotive lightweighting. Magnesium alloys, which are the lightest metallic structural materials at present, are superior choices for lightweighting because of their low density, high strength, and excellent casting performance. Magnesium alloy gigacasting has enormous potential for automotive applications, enabling the production of lightweight automotive components with superior mechanical properties. However, this process faces challenges because magnesium alloys' active chemical properties and high susceptibility to hot tearing, combined with their large size, thin wall thickness, and complex geometries, make defects like porosity and hot tearing prevalent. These defects greatly impair the performance of gigacast components. Preventing and mitigating casting defects is critical for improving the yield and quality stability of magnesium alloy gigacastings, thereby facilitating their widespread application in industries like automotive and aerospace. To address these issues, the causes and control measures for three common defects (porosities, defect bands, and hot tearing) are briefly explored in this study. Progress and challenges in defect control, focusing on melt treatment, alloy development, process optimization, and structural design, are also outlined. This review aims to provide valuable insights into defect control strategies for developing high-performance magnesium alloy gigacastings.

Key words： magnesium alloy gigacasting process defect microstructure process

收稿日期: 2024-09-03

ZTFLH:

TG292

基金资助:国家重点研发计划项目(2021YFB3701000);国家自然科学基金项目(52471118);国家自然科学基金项目(U21A2048);中国科协青年人才托举工程项目(2022QNRC001)

通讯作者: 张昂，angzhang@cqu.edu.cn，主要从事新型镁合金材料及先进制备加工技术研究

Corresponding author: ZHANG Ang, Tel: 18811328068, E-mail: angzhang@cqu.edu.cn

作者简介: 蒋斌，男，1975年生，教授，博士

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Defect	Characteristic	Cause	Prevention measure
Gas porosity	Round and oval shape with smooth surface	Gas trapped during die casting process and gas generated by the decomposition of mold release agent	Equipping vacuum system, reasonable selection of process parameters and coating, and control of the amount of spraying
Adhesion	Strip-shaped scratches along the mold-opening direction on the casting surface	Damaged or rough mold surface, high casting temperature or mold temperature, and bad release agent effect	Repair the damaged part of the mold surface, adjust the balance of the ejector rods, use the release agent with good release effect, and adjust the pouring and mold temperatures
Cold shut	Irregular sunken linear lines on the casting surface	Poor fluidity of the alloy melt, low filling rate, low pouring temperature, and low mold temperature	Increase the pouring temperature, shorten the filling time, enhance the fluidity of the liquid metal, and improve the injection rate
Defect band	A band of pores with solute segregation, distributed near the casting surface and some also in the core area	The shear force in the solid-liquid two-phase region causes the fragmentation, remelting, and coalescence of externally solidified crystals. It is difficult for liquid metal to fill at late solidification, resulting in a large number of pores	Increase the shear force, by increasing the injection rate and adjusting the vacuum time, to break externally solidified crystals
Undercasting	Insufficient filling parts or incomplete casting contour	Poor fluidity, low pouring temperature, low mold temperature, too much involved gas, and poor operation	Optimize the alloy composition and improve pouring and mold temperatures
Flow mark	Clearly visible, non-directional stripes that differ in color from the metal matrix	Low mold temperature, splashing due to too small cross-section area and inappropriate position of the inner gate, insufficient pressure on the metal, and too much coating	Raise the mold temperature, adjust the cross-sectional area and position of the inner gate, adjust the injection rate and pressure, and use appropriate amount of coating
Deformation	Overall or partial deformation of the casting	Poor structural design, insufficient casting rigidity due to premature mold opening, uneven force during ejection caused by unreasonable setting of ejector rods	Improve casting structure, adjust mold opening time, reasonably set the number and position of ejector rods, and eliminate mold pulling problem
Burr	Metal flakes appear on the edge of the parting surface	High injection rate, insufficient locking force, high pouring temperature, and worn and deformed hinge of die casting machine	Check the locking force, correct the mold, clean the cavity and parting surface, and reduce poring temperature and the injection rate
Slag inclusion	Irregular impurities on the casting surface and inside the casting	Unclean furnace materials, insufficient alloy purification, unclean casting mold, and slag and oxides brought into melt	Ensure the cleanliness of furnace materials, refine melt, and promptly clean the mold
Crack	Network-like protrusions or indentations resembling hairs on the casting surface	Cracks on the surface of the mold cavity, high pouring temperature, rough surface of the mold cavity	Select high-quality mold materials, avoid too high pouring temperature, and sufficient and uniform mold preheating
Drawing die	Difficult to smoothly demold	Insufficient mold surface roughness, carbon deposits and oxidation on the mold surface, improper or insufficient use of lubricants, unreasonable design of mold structure	Spray special coatings, perform surface treatment on the mold surface, select appropriate lubricants, and minimize mold deformation and wear

表1 压铸中常见的缺陷类型

图1 典型缺陷形貌[29,32,33]

图2 气泡动力学和枝晶-气泡相互作用模拟[35,39]

图3 镁熔体无熔剂连续精炼系统原理图[76]

图4 基于典型结构特征的“局部”-“整体”协同设计

图5 材料-结构-性能一体化优化设计

图6 镁合金仪表盘支架压铸缺陷模拟预测

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