高压铸造铝合金的流动性、组织特征及解析模型
收稿日期: 2025-09-09
修回日期: 2026-03-06
网络出版日期: 2026-03-19
基金资助
国家重点研发计划项目(2022YFB3404201)
Fluidity, Microstructural Characteristics, and Analytical Models of High-Pressure Die-Cast Aluminum Alloys
Received date: 2025-09-09
Revised date: 2026-03-06
Online published: 2026-03-19
Supported by
National Key Research and Development Program of China(2022YFB3404201)
高压铸造凭借高速充型与快速凝固的特点，已成为新能源汽车大型一体化铝合金结构件的关键成形技术。然而，在大型薄壁铸件中，熔体流动行为与组织缺陷演化之间存在复杂的耦合关系，其机理仍缺乏系统认识。本文系统综述了高压铸造铝合金流动性的研究进展，并从工艺参数、微观组织和解析模型三个方面构建统一的分析框架。首先，总结了压铸条件下流动性的影响因素，指出工艺参数和合金设计共同通过调控传热与凝固过程来改变流动性。其次，阐明了压铸件典型层状组织(皮肤层、缺陷带和外部凝固晶体)的形成机制，并指出了流动过程中枝晶网络连通、溶质富集及孔洞演化对流动终止的关键作用。最后，分析了各种流动解析模型在物理假设与预测能力方面的差异。综上，压铸流动性的本质是热-相-流三场耦合作用的结果。并指出未来需在停止流动机理、同步辐射原位表征及数据驱动方面作进一步深入研究。
熊守美 , 何祖年 . 高压铸造铝合金的流动性、组织特征及解析模型[J]. 金属学报, 2026 , 62(5) : 941 -958 . DOI: 10.11900/0412.1961.2025.00266
High-pressure die casting (HPDC), characterized by high filling speeds and rapid solidification, has become a key manufacturing process for large integrated aluminum alloy structural components in electric vehicles. However, in large thin-walled castings, complex coupling exists between melt flow behavior and the evolution of microstructural defects, and the underlying mechanisms remain insufficiently understood. This paper systematically reviews recent progress in the fluidity of aluminum alloys under HPDC conditions and establishes a unified analytical framework from three perspectives: process parameters, microstructural characteristics, and analytical models. First, the factors influencing fluidity in die casting are summarized, highlighting that both processing parameters and alloy design jointly affect fluidity by regulating heat transfer and solidification processes. Second, the formation mechanisms of the characteristic layered microstructure in die castings, including the skin layer, defect band, and externally solidified crystals (ESCs), are elucidated. The critical roles of dendritic network connectivity, solute enrichment, and pore evolution in flow stoppage are also discussed. Finally, the differences among various analytical models for fluidity are compared in terms of their physical assumptions and predictive capabilities. Overall, the fluidity of die cast alloys is governed by the coupled interactions of thermal, phase transformation, and flow fields. Future research should further focus on the mechanisms of flow stoppage, in situ synchrotron characterization, and data-driven approaches.
Key words： high-pressure die casting; aluminum alloy; fluidity
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