Abstract
This study demonstrates the feasibility of a novel casting process called tailored additive casting (TAC). The TAC process involves injecting the melt several times to fabricate a single component, with a few seconds of holding between successive injections. Using TAC, we can successfully produce commercial-grade automotive steering knuckles with a tensile strength of 383 ± 3 MPa and an elongation percentage of 10.7 ± 1.1%, from Al 6061 alloys. To produce steering knuckles with sufficient mechanical strength, the composition of an Al 6061 alloy is optimized with the addition of Zr, Zn, and Cu as minor elements. These minor elements influence the thermal properties of the melt and alloy, such as their thermal stress, strain rate, shrinkage volume, and porosity. Optimal conditions for heat treatment before and after forging further improve the mechanical strength of the steering knuckles produced by TAC followed by forging.
Highlights
Metal casting is one of the oldest manufacturing processes, in which molten metal is poured into a mold to form the desired shape and allowed to solidify [1]
Al alloys by analyzing their thermal properties, such as thermal stress, shrinkage knuckles, we evaluate various compositions of Al alloys by analyzing their thermal properties, such starting temperature (SST), shrinkage characteristics, poreshrinkage formation.characteristics, In addition, likeand previous as thermal stress, shrinkage starting temperature and (SST), pore studies, we perform forging and heat treatment to further improve the mechanical strength of the formation
We prepared 5 kg of melt for each of the five alloys listed in Table 1 and, after holding the melts at 1163 K for 3 h to ensure that all additions were fully dissolved, we measured the thermal stress, SST, shrinkage volume, and porosity
Summary
Metal casting is one of the oldest manufacturing processes, in which molten metal is poured into a mold to form the desired shape and allowed to solidify [1]. Alloys with highstrength mechanical tiltthe casting process, to their highdue melt withThe high mechanical yet strength yet high melt viscosity are used in continuous casting, by which castings with only simple high melt viscosity are used in continuous casting, by which castings with only simple geometry geometry can be produced These alloys are applicable not applicable to fabricate castingswith with complex complex can be produced. Superiority of our method by fabricating steering knuckles with outstanding mechanical strength as shown in 6061. Al alloys by analyzing their thermal properties, such as thermal stress, shrinkage knuckles, we evaluate various compositions of Al alloys by analyzing their thermal properties, such starting temperature (SST), shrinkage characteristics, poreshrinkage formation.characteristics, In addition, likeand previous as thermal stress, shrinkage starting temperature and (SST), pore studies, we perform forging and heat treatment to further improve the mechanical strength of the formation.
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