Semi-Solid Die Cast Battery Bracket Strength
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Solution Overview
Problem
Existing battery brackets formed by semi-solid die casting have insufficient strength and are prone to damage under complex stress conditions in commercial vehicles.
Innovation Solution
A method involving semi-solid die casting of an aluminum alloy, where the process includes heating the alloy, stirring it to create a semi-solid slurry, die-casting into a mold with strategically placed gates for threaded connections, and subsequent solution and aging treatments to enhance mechanical properties and thread strength, using a high-strength Al—Si—Cu—Mg alloy with specific temperature and stirring parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If semi-solid die casting is used to prepare battery bracket, then manufacturing efficiency is improved, but the strength of the battery bracket becomes insufficient
Solution Approach 1:
The patent applies parameter changes by precisely controlling the superheat temperature of the aluminum alloy liquid (maintaining 50-100°C above melting point) and the injection pressure (15-30 MPa) during semi-solid die casting. These parameter optimizations ensure the alloy maintains appropriate fluidity for complex thread formation while achieving sufficient strength in the final product, resolving the contradiction between manufacturing efficiency and strength
Solution Approach 2:
The patent implements preliminary action through pre-heating the die cavity to 100-200°C before injection and maintaining the aluminum alloy liquid at controlled superheat temperature. This preliminary thermal preparation prevents premature solidification during injection, ensuring complete filling of complex threaded structures while maintaining manufacturing efficiency and product strength
2Device complexity
If complex threaded structures are formed by semi-solid die casting, then integration of components is improved, but the thread strength becomes insufficient
Solution Approach 1:
The patent uses parameter changes by optimizing injection pressure (15-30 MPa) and holding pressure (20-40 MPa) specifically for threaded regions. The extended holding time (10-20 seconds) allows complete filling and proper solidification of complex thread structures, ensuring both integration and sufficient thread strength are achieved simultaneously
Solution Approach 2:
The patent applies preliminary action by pre-heating the die cavity to 100-200°C before injection. This preliminary thermal preparation prevents premature solidification during injection, ensuring complete filling of complex threaded structures and proper formation of integrated components with adequate strength
3Strength
If traditional materials are used for battery bracket, then strength is sufficient, but the weight becomes excessive
Solution Approach 1:
The patent applies parameter changes by precisely controlling the composition of aluminum alloy (adding 0.5-2.0% Cu, 0.1-0.5% Mg, 0.1-0.3% Ti), superheat temperature (50-100°C above melting point), and injection parameters. These optimizations enable aluminum alloy to achieve sufficient strength while maintaining the weight advantage over traditional steel materials
Solution Approach 2:
The patent implements composite materials by creating a semi-solid aluminum alloy composite with controlled distribution of reinforcing phases (Ti additions) and optimized matrix composition. This composite structure maintains the lightweight advantage of aluminum while achieving strength comparable to traditional materials through controlled microstructure and phase distribution
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 significantly increases the strength of the battery bracket, particularly at stressed threads, extends its service life, and reduces weight by more than 70% compared to traditional materials, while maintaining excellent mechanical properties.
Implementation Method 1
heating the aluminum alloy raw material in the melting furnace to obtain liquid aluminum alloy
Implementation Method 2
stirring the liquid aluminum alloy by the slurry machine to obtain a semi-solid slurry
Implementation Method 3
die-casting the semi-solid slurry into a battery bracket mold via the die-casting machine for die-casting forming
Implementation Method 4
subjecting the formed prototype of the battery bracket to solution treatment at a second preset temperature
Implementation Method 5
then to aging treatment at a third preset temperature to obtain the battery bracket
Data Source
AI summary
A method for forming a battery bracket by semi-solid die casting, where the battery bracket is prepared by semi-solid die casting. The method includes: preparing an aluminum alloy raw material into liquid aluminum alloy, and incubating the liquid aluminum alloy at a first preset temperature; delivering the liquid aluminum alloy to a slurry machine for stirring to obtain a semi-solid slurry; pouring the semi-solid slurry into a die-casting machine for die-casting forming to obtain a prototype of the battery bracket; and subjecting the formed prototype of the battery bracket to solution treatment at a second preset temperature and then to aging treatment at a third preset temperature to obtain the battery bracket; where, the battery bracket mold structurally matches the battery bracket, and gates are disposed at positions in the battery bracket mold corresponding to threaded connections of a first boss and a second boss of the battery bracket, respectively.