The Capacity for Energy Absorption is being evaluated

  • When it comes to functional integration, die casting mould aluminum parts have a tremendous amount of potential, which is a fundamental concept in light weight design. The LKR Leichtmetallkompetenzzentrum Ranshofen (LKR) has developed a test geometry that allows coupon and component testing to be performed from a single cast part with the least amount of geometrical influence possible.

    The first paragraph is an introduction.

    aluminum die castings aluminum parts are becoming increasingly popular for use as structural components, as evidenced by the increase in interest in their use. The ability to quantify and determine the operational applicability of novel ductile cast alloys requires the development of standardized and reproducible methods for determining their energy absorption capability. Energy absorption, on the other hand, is always defined as an interaction between the material and the geometry. When it comes to characterization, the finished component's geometry is frequently unsuitable due to the possibility of effects occurring that are more a result of the geometry than the material. To this end, LKR has designed and built a cast aluminum pipe that can be used as a macroscopic test geometry to characterize aluminum cast alloys, both experimentally and numerically, at the coupon and component levels.

    The geometric design of the custom die casting pipe was determined on the basis of structural mechanical simulations, with consideration given to the sampling of material properties and the characterization of the crash behavior of the pipe.

    Additionally, filling and solidification simulations were used to investigate the castability of the material, in addition to its geometric properties. The final design of the cast pipe is shown in this illustration.

    Creating a mold

    First and foremost, the research activities at LKR were focused on implementing the test geometry on the fully automated HPDC cell that was then made available to the researchers. Casting tests were conducted with a focus on the mold filling behavior through several iteration loops in order to determine the corresponding pouring curve for the best possible quality. The vacuum unit was added to the process in order to further optimize it, and it has proven to be beneficial in terms of component quality and failure mechanism of the cast parts.

    Various aluminum alloys were successfully produced during the casting trials and then subjected to heat treatment after they were finished. The purpose of these casting trials was to confirm the suitability of the overall concept and to establish a benchmark for the material properties of existing alloys by comparing them to one another.

    Immediately following the trials on the HPDC machine, the zinc castings pipes were subjected to experimental characterisation.