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10.3390/ma17122835
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Article

Development of the Low-Pressure Die Casting Process for an Aluminium Alloy Part

by
Filipe Monteiro
1,*,
Gonçalo Soares
1,
Rui Madureira
1,
Rui Pedro Silva
1,
José Silva
1,
Rui Amaral
1,
Rui Neto
1,2,
Ana Reis
1,2 and
António Esteves
3
1
INEGI—Institute of Science and Innovation in Mechanical and Industrial Engineering, Rua Dr. Roberto Frias, 4200-465 Porto, Portugal
2
Department of Mechanical Engineering, Faculty of Engineering, University of Porto, Rua Dr. Roberto Frias, 4200-465 Porto, Portugal
3
FAB–Fundição de Alumínios de Braga, Parque Industrial Sobreposta, Lugar da Alagoa, Este (São Pedro e São Mamede), 4715-533 Braga, Portugal
*
Author to whom correspondence should be addressed.
Materials 2024, 17(12), 2835; https://doi.org/10.3390/ma17122835
Submission received: 9 May 2024 / Revised: 6 June 2024 / Accepted: 7 June 2024 / Published: 10 June 2024
(This article belongs to the Section Metals and Alloys)
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Abstract

The low-pressure die casting (LPDC) process was experimentally and numerically studied to produce AlSi7Mg0.3 components such as steering knuckles. Steering knuckles are important safety components in the context of a vehicle’s suspension system, serving as the mechanical interface that facilitates the articulation of the steering to control the front wheel’s orientation, while simultaneously bearing the vertical load imposed by the vehicle’s weight. This work focuses on the development of a numerical model in ProCAST®, replicating the production of the aforementioned part. The model analyses parameters such as the filling dynamics, solidification process, and presence of shrinkage porosities. For the purpose of evaluating the quality of the castings, six parts were produced and characterised, both mechanically (tensile and hardness tests) and microstructurally (porosity and optical microscopy analysis). When correlating simulation results with the available experimental data, it is possible to conclude that the usage of the LPDC process is a viable alternative to the use of steels and other metals for the production of very high-quality castings while using lighter alloys such as aluminium and magnesium in more demanding applications.
Keywords: low-pressure die casting; AlSi7Mg0.3; ProCAST®; lightweight; mobility low-pressure die casting; AlSi7Mg0.3; ProCAST®; lightweight; mobility

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MDPI and ACS Style

Monteiro, F.; Soares, G.; Madureira, R.; Silva, R.P.; Silva, J.; Amaral, R.; Neto, R.; Reis, A.; Esteves, A. Development of the Low-Pressure Die Casting Process for an Aluminium Alloy Part. Materials 2024, 17, 2835. https://doi.org/10.3390/ma17122835

AMA Style

Monteiro F, Soares G, Madureira R, Silva RP, Silva J, Amaral R, Neto R, Reis A, Esteves A. Development of the Low-Pressure Die Casting Process for an Aluminium Alloy Part. Materials. 2024; 17(12):2835. https://doi.org/10.3390/ma17122835

Chicago/Turabian Style

Monteiro, Filipe, Gonçalo Soares, Rui Madureira, Rui Pedro Silva, José Silva, Rui Amaral, Rui Neto, Ana Reis, and António Esteves. 2024. "Development of the Low-Pressure Die Casting Process for an Aluminium Alloy Part" Materials 17, no. 12: 2835. https://doi.org/10.3390/ma17122835

APA Style

Monteiro, F., Soares, G., Madureira, R., Silva, R. P., Silva, J., Amaral, R., Neto, R., Reis, A., & Esteves, A. (2024). Development of the Low-Pressure Die Casting Process for an Aluminium Alloy Part. Materials, 17(12), 2835. https://doi.org/10.3390/ma17122835

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