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Use of Selective Laser Melting (SLM) as a Replacement for Pressure Die Casting Technology for the Production of Automotive Casting

Piekło J., Garbacz-Klempka A.

Archives of Foundry Engineering

2021

Vol. 21, iss. 2

9--16

Selective laser melting is one of the additive manufacturing technologies that is used to produce complex-shaped components for applications in the automotive industry. The purpose of the changes in the design, technology, and material tests was to make a steering gear housing using the SLM method. The steering gear housing was produced by the pressure casting method using an AlSi9Cu3(Fe) alloy. The construction of this housing is adapted to the specifics of left-hand traffic. The change in technology was related to the change of the position of the steering system from right-hand to left-hand and the demand for a limited number of gear housings. It was necessary to make a virtual model of the housing on the basis of the part that was removed from the vehicle. In SLM technology, the AlSi10Mg aluminum alloy was used as a raw material in the form of CL 32Al gas-atomized powder. After the SLM process was completed, the housings were subjected to heat treatment. The AlSi10Mg alloy fabricated by the SLM method after heat treatment is characterized by good plasticity and an average value of tensile strength. The last stage was to check the geometry of the SLM housing with a 3D scanner. As a result, a map of the dimensional deviations from the nominal values was obtained. This data was used to modify the CAD model before the next fabrication process. The use of 3D printing technology allowed for the quick production of elements. The time to develop the technology and the production of the first two gear housings based on a 3D model was seven days.

Prediction of mechanical, structural and internal-stress properties of automotive castings

Čech J., Zemčik L., Bařinova D.

Archiwum Odlewnictwa

2001

R. 1, nr 2

424--431

This paper describes the experimental and simulation methods applied in the testing of a gravity-poured ductile-iron casting, called cylinder head cover for cars. Prediction of tensile strength, combined with measuring the speed of ultrasound waves, leads to very good results that are applicable in practice. Analyses of the microstructure of cylinder head covers show that the contents of pearlite and ferrite correspond with the values acquired by simulation. The values specifying the number of graphite particles per 1 mm2 of material correspond with the values measured. By measuring internal stress with the aid of strain gauges and subsequently by simulation, the technician and design engineer can verify the effectiveness of heat treatment and test dangerous parts of a casting from the perspective of internal stress.

Artykuł opisuje eksperymentalne i symulacyjne metody zastosowane do testowania grawitacyjnego odlewu pokrywy głowicy cylindrów z żeliwa sferoidalnego. Przewidywanie wytrzymałości na rozciąganie połączone z pomiarem szybkości fal ultradźwiękowych daje bardzo dobre wyniki, co umożliwia praktyczne zastosowanie tej metody. Analiza mikrostruktury pokrywy cylindra pokazuje, że zawartość perlitu i ferrytu koreluje z wartościami uzyskanymi z symulacji. Wartości określające ilość sferoidów na 1mm2 dla materiału korelują z wartościami zmierzonymi. Poprzez pomiar naprężeń wewnętrznych z zastosowaniem metody tensometrycznej i późniejsza symulację, technicy i projektanci mogą weryfikować efektywniej procesy obróbki cieplnej i sprawdzać niebezpieczne miejsca z perspektywy naprężeń wewnętrznych.