Optimization of Engine Block Casting Process Based on New Aluminum Alloy Material of Al–Si–Cu System.

This study conducted molding process research on castings of complex engine blocks with a new Al–Si–Cu aluminum alloy material. Numerical simulation and experimental validation were used to investigate the effects of different pouring system design schemes on the casting performance, defect formation and mechanical properties of aluminum alloy castings. Based on the casting structure and alloy casting properties, three types of casting systems (i.e., A, B, and C) were designed and analyzed by numerical simulation and testing. The study shows that the molding process of casting system scheme C is more optimal, the numerically simulated porosity is reduced by 4.13 and 1.9% compared with those of schemes A and B, respectively, the defect volume is reduced by 205.87 and 94.7 cm3 compared with those of schemes A and B, respectively, and the average cooling rate is improved by 47.6 and 26.5% compared with those of schemes A and B, respectively. After experimental verification, casting system C exhibited optimal mechanical properties, good CT scan and the microstructure of aluminum alloy analysis results, and numerical simulation results consistent with the actual trial production results, providing guidance for relevant theoretical research. [ABSTRACT FROM AUTHOR]