Optimized Semi-Solid Slurry Aluminum Die Casting for HPDC Structural Components
2022-01-0283
03/29/2022
- Event
- Content
- Electric Vehicles (EV) are transforming the automobile industry by creating a renewed approach to propulsion through battery powered electric drive unit (EDU). Key to the success of the EV industry is vehicle drive range on a fully charged battery. That limit state is dependent on many factors, but one critical one is vehicle mass. Vehicle mass is a parasitic loss in energy consumption; and therefore, the mass of EV has been valued at much higher levels than for internal combustion engine vehicles. Therefore, finding opportunities for light weight options is crucial. In this paper, optimization method for aluminum semi-solid slurry die cast (SSD) for high pressure die casting (HPDC) will be discussed. A novel approach to slurry preparation, transfer, die operation, and post cast process was developed and was proven on structural components of EDU mounting system. 40% part mass saving was achieved in a study case compared to baseline conventional HPDC design. On average, it is anticipated that about 20% mass savings should be achieved in load bearing structural components using the SSD method vs conventional HPDC. Two distinct methods for preparing the slurry were studied: Swirled Enthalpy Equilibration Device (SEED) method, and Gas-induced Semi-Solid Slurry (GISS) Method. In this paper, process optimization parameters and process controls will be discussed, and production-intent EDU mount bracket optimization study will be presented. The improved SSD method has potential application in many components of the vehicle, and the need to develop the supply base globally will be pressing.
- Citation
- Jomaa, S., Risko, F., Xu, Y., Liang, X. et al., "Optimized Semi-Solid Slurry Aluminum Die Casting for HPDC Structural Components," SAE Technical Paper 2022-01-0283, 2022, .