目的 解决传统锻造成形工艺（生产效率低、后续加工量大、成本高）和低压铸造成形工艺（压力不足、成形缺陷多、力学性能差）在铝合金衬套外管制造中的技术瓶颈,提出挤压铸造成形新方法。方法 基于ProCAST数值模拟与挤压铸造实验平台,研究不同挤压速度对A356铝合金衬套外管成形质量的影响,结合扫描电镜及力学性能测试,揭示工艺参数-微观组织-宏观性能的关联机制。结果 当挤压速度为0.4 m/s时,铸件内部有缩松缩孔,且经过T6热处理后,缩松缩孔位置出现鼓包,此时屈服强度为231.59 MPa,抗拉强度为280.68 MPa,延伸率为4%。当挤压速度降低至0.3 m/s时,铸件内部缩松缩孔基本消失,屈服强度达到255.89 MPa,抗拉强度达到327.91 MPa,延伸率达到13.6%,较0.4 m/s工况下分别提升了10.5%、16.8%和2.4倍,并达到屈服强度≥250 MPa、抗拉强度≥310 MPa、延伸率≥9%的力学性能要求。微观组织显示,与挤压速度0.4 m/s相比,0.3 m/s工况下α-Al基体晶粒尺寸更小,且分布更为均匀细化,Al-Si共晶相更细化且分布更均匀,韧窝密度更大,而0.4 m/s工况存在粗大Al-Si相和孔洞缺陷,会因为Al-Si相的不均匀分布以及孔洞分布而更容易产生应力集中和裂纹扩展现象。工艺优化后,综合合格率达97.5%。结论 挤压速度0.3 m/s可显著提升衬套外管的成形质量与力学性能,其强化机制归因于细晶强化与缺陷抑制的协同作用,优化后的工艺满足工程应用需求,为高强铝合金复杂构件成形提供了新策略。
Abstract
To address the technical limitations of traditional forging (low productivity, excessive post-processing, high cost) and low-pressure casting (insufficient pressure, formation defects, and weak mechanical properties) in manufacturing outer bushing tubes for aluminum alloys, the work aims to propose an extrusion casting method. By combining ProCAST numerical simulations with experimental extrusion casting tests, the effects of extrusion speeds on the forming quality of A356 aluminum alloy components were investigated. The correlation mechanism between process parameters, microstructure and macro performance was revealed through scanning electron microscopy and mechanical property testing. When the extrusion speed was 0.4 m/s, shrinkage porosity and cavities formed inside the casting. After T6 heat treatment, bulges appeared at the locations of these defects. Under these conditions, the yield strength was 231.59 MPa, the tensile strength was 280.68 MPa, and the elongation was 4%. When the extrusion speed was reduced to 0.3 m/s, the internal shrinkage porosity and cavities in the casting were essentially eliminated. The yield strength reached 255.89 MPa, the tensile strength reached 327.91 MPa, and the elongation reached 13.6%. Compared to the conditions at 0.4 m/s, these values represented increases of 10.5%, 16.8%, and 2.4 times, respectively. Furthermore, this met the mechanical property requirements of yield strength ≥250 MPa, tensile strength ≥310 MPa, and elongation ≥9%. Microstructural analysis revealed that under the 0.3 m/s extrusion condition, the α-Al matrix grains exhibited finer sizes compared to those formed at 0.4 m/s, with refined and uniformly distributed Al-Si eutectic phases accompanied by high dimple density. In contrast, the 0.4 m/s condition resulted in coarse Al-Si phases and pore defects. The inhomogeneous distribution of Al-Si phases and localized pore clusters under higher extrusion speeds promoted stress concentration and facilitated crack propagation. Through process optimization, the comprehensive qualification rate reached 97.5%. The extrusion speed of 0.3 m/s can significantly improve the forming quality and mechanical properties of the outer bushing tube, of which the strengthening mechanism is attributed to the synergistic effect of grain refinement strengthening and defect suppression. The optimized process meets the requirements of engineering applications and provides a new strategy for the forming of high-strength aluminum alloy complex components.
关键词
衬套外管 /
挤压铸造 /
A356铝合金 /
挤压速度 /
数值模拟
Key words
outer bushing tube /
extrusion casting /
A356 aluminum alloy /
extrusion speed /
numerical simulation
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基金
国家自然科学基金（52075272）; 宁波市重点研发计划暨“揭榜挂帅”项目（2023Z037）
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