A study of thin-walled ZL105A casting manufactured by vacuum differential pressure casting

摘要

The casting with more than 70% thin-walled parts and minimum wall thickness of 2 mm was manufactured by vacuum differential pressure casting (VDPC). The shower gating system was used to ensure smooth filling of melt. The top risers were replaced by chills and the positions of the chills were optimized to eliminate defects in hot spot place. The rational assembling of gating system and chill ensure the progressive solidification of the casting. Moreover, the optimal process parameters were determined as follows: vacuum degree 0MPa, filling pressure 0.1MPa, filling velocity 3.5cm/s, rising pressure velocity 0.02MPa/s, dwell pressure 0.15MPa and pressure holding time 7min. The simulation results indicated that the optimized gating system and process parameters could ensure complete filling and progressive solidification of the thin-walled casting. The X-ray and mechanical performances results showed that the complicated and precise aluminum alloy casting could be manufactured by using optimal gating system and casting process parameters.