Ultra-large aluminum shape casting:Opportunities and challenges  

作　　者：Qi-gui Wang Andy Wang Jason Coryell 

机构地区：[1]Advanced Materials Technology&Virtualization,GM Global Technical Center,Warren,MI USA

出　　处：《China Foundry》2024年第5期397-408,共12页中国铸造（英文版）

摘　　要：Ultra-large aluminum shape castings have been increasingly used in automotive vehicles,particularly in electric vehicles for light-weighting and vehicle manufacturing cost reduction.As most of them are structural components subject to both quasi-static,dynamic and cyclic loading,the quality and quantifiable performance of the ultra-large aluminum shape castings is critical to their success in both design and manufacturing.This paper briefly reviews some application examples of ultra-large aluminum castings in automotive industry and outlines their advantages and benefits.Factors affecting quality,microstructure and mechanical properties of ultra-large aluminum castings are evaluated and discussed as aluminum shape casting processing is very complex and often involves many competing mechanisms,multi-physics phenomena,and potentially large uncertainties that significantly influence the casting quality and performance.Metallurgical analysis and mechanical property assessment of an ultra-large aluminum shape casting are presented.Challenges are highlighted and suggestions are made for robust design and manufacturing of ultra-large aluminum castings.

关 键 词：ultra-large castings ALUMINUM light-weighting quality microstructure materials properties 

分 类 号：TG146.21[一般工业技术—材料科学与工程]