Extrusion Casting Process of Outer Bushing Tubes for A356 Aluminum Alloy

LIU Yagang; HU Jiangpin; WU Xiaocheng; PENG Wenfei; FENG Guangming; SHAO Yiyu; ZHANG Fuxin; GAO Yinghao

doi:10.3969/j.issn.1674-6457.2026.01.005

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (1) : 46-56. DOI: 10.3969/j.issn.1674-6457.2026.01.005

Light Alloy Forming

Extrusion Casting Process of Outer Bushing Tubes for A356 Aluminum Alloy

LIU Yagang¹, HU Jiangpin¹, WU Xiaocheng^2,*, PENG Wenfei², FENG Guangming¹, SHAO Yiyu², ZHANG Fuxin³, GAO Yinghao⁴

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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.

Key words

outer bushing tube / extrusion casting / A356 aluminum alloy / extrusion speed / numerical simulation

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LIU Yagang, HU Jiangpin, WU Xiaocheng, PENG Wenfei, FENG Guangming, SHAO Yiyu, ZHANG Fuxin, GAO Yinghao. Extrusion Casting Process of Outer Bushing Tubes for A356 Aluminum Alloy[J]. Journal of Netshape Forming Engineering. 2026, 18(1): 46-56 https://doi.org/10.3969/j.issn.1674-6457.2026.01.005

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