die-casting aluminum wheel

pressure die casting (LPDC) of an aluminum wheel. By analyzing the mold-fi lling and solidifi cation stage of the LPDC process, the distribution of liquid fraction, temperature field and solidification pattern of castings were studied. The potential shrinkage defects were predicted to be formed at the rim/spoke junctions, which is in consistence with the X-ray detection result. The distribution pattern of the defects has also been studied. A solution towards reducing such defects has been presented. The cooling capacity of the mold was improved by installing water pipes both in the side mold and the top mold. Analysis on the shrinkage defects under forced cooling mode proved that adding the cooling system in the mold is an effective method for reduction of shrinkage defects. Key words: numerical simulation; aluminum wheel; low pressure die casting; defect reduction; forced cooling CLC number: TG146.2+1/TP391.9 Document code: A Article ID: 1672-6421(2009)01-048-05 The automotive industry is moving towards expanding the application of light-weight aluminum alloy castings for various components that previously made from steels or cast irons, for example, more than 50 % of new cars in North America are now equipped with aluminum alloy wheels [1]. Unfortunately, because of the multiple stringent requirements for surface finish, impact and fatigue performance, ai