Abstract
In modern automotive structural components, metal sheets are combined with casting parts to enable a light and mechanical stable structure. In this study, the bonding between steel metal sheets and aluminium casting parts are performed as part of the high pressure die casting (HPDC) process. In this way additional bonding steps like welding can be omitted, which saves time and energy. The combination of sheet metal and cast is achieved by a structured surface (ribs) of the sheet, which is filled in the casting process with the liquid aluminium alloy and leads to a mechanical connection after solidification. Coupled flow and solidification simulation is used to analyse the hybrid casting process with a focus on the rapid solidification inside the ribs. A high-resolution (mesoscale) simulation of the interface between metal sheet and aluminium alloy during filling and solidification can capture the details of melt flow and rapid solidification. By coupling the mesoscale flow and solidification simulations to multiphase field simulations on the microscale, the resulting microstructure can be calculated. The solidification conditions inside the ribs as result of the mesoscale simulation can be validated by comparing the calculated microstructure with experimental results found in real castings, performed on a cold-chamber HPDC machine.
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