Segmented Permanent Mold Casting for AlSiZnMg Chassis Parts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing motor vehicle chassis parts using artificially ageing alloys are costly and time-consuming due to the need for precise heat treatment, which limits the adaptation of microstructure to varying stress conditions across the cross-section, resulting in suboptimal mechanical strength and ductility.
Innovation Solution
A method and device for producing chassis parts using a naturally aging AlSiZnMg alloy, where the alloy is cast in a segmented permanent mould with controlled cooling and heating to create an interdendritic, eutectic mixed crystal structure, allowing for adjustable mechanical strength, ductility, and temperature stability across the cross-section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If artificially ageing alloys are used with gravity casting or low-pressure casting, then mechanical strength can be achieved, but the production process becomes costly and time-consuming due to precise heat treatment requirements
Solution Approach 1:
The patent changes the alloy composition parameters by using naturally aging AlSiZnMg alloys with specific element ranges (Si: 5-11%, Zn: 4-9%, Mg: 0.2-1.0%, Sr: 60-500 ppm) instead of traditionally artificially aged alloys, eliminating the need for complex heat treatment processes while maintaining mechanical strength
Solution Approach 2:
The patent extracts and removes the heat treatment process from the production sequence by using naturally aging alloys that achieve their desired mechanical properties through controlled solidification and natural aging, thereby simplifying the manufacturing process and improving productivity
2Ease of manufacture
If uniform heat treatment is applied to the complete component, then processing simplicity is maintained, but the micro-structure cannot be optimally adapted to varying stress conditions across the cross-section
Solution Approach 1:
The patent applies local quality by creating different micro-structures in different regions of the casting through selective cooling and heating of specific mold segments, allowing each region to have an optimized micro-structure adapted to its specific stress conditions while using a single naturally aging alloy composition
Solution Approach 2:
The patent segments the permanent mold into multiple independently controllable segments that can be cooled or heated differently, enabling localized control of solidification and micro-structure formation in response to varying stress distributions across the component cross-section
3Strength
If strict temperature control is maintained during heat treatment, then mechanical strength values are achieved, but the annealing furnaces require very small spatial variation in temperature increasing process complexity
Solution Approach 1:
The patent changes the approach from active temperature control during heat treatment to passive temperature control during solidification by using naturally aging alloys with specific compositional parameters, eliminating the need for complex annealing furnace temperature control systems while maintaining mechanical strength consistency
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves high yield strength, excellent temperature stability, and low porosity, with mechanical strength values consistent across all cross-sections, while maintaining good strain properties and corrosion resistance.
Implementation Method 1
the individual segments of the permanent mould being cooled or heated in a zone of punctiform to surface-like configuration
Implementation Method 2
immediately after solidification, being removed from the mould and naturally aged
Implementation Method 3
consisting of Al mixed crystals and AlSi eutectic with coherent phases formed by precipitations of MgZn2 and/or Mg3Zn3Al2
Implementation Method 4
coherent phases formed by precipitations of MgZn2 and/or Mg3Zn3Al2
Implementation Method 5
the eutectic melt is intermittently cooled or heated, at a rate of cooling of 0.01 to 10° C./s, to obtain a pasty solidification with intermetallic phases
Implementation Method 6
intermetallic phases that are interdendritically distributed in the AlSi eutectic
Data Source
AI summary
A method and device for producing motor vehicle chassis parts is provided. The motor vehicle chassis parts can be subjected to tensile stress, compressive stress and torsion and the mechanical strength of the motor vehicle chassis parts can be adjusted over the respective cross-section. The motor vehicle chassis parts have high ductility and temperature stability and are made of an AlSiZnMg alloy by permanent mold casting.