CN111549263B - Aluminum alloy integrated electric drive assembly installation frame and low-pressure casting method thereof - Google Patents
Aluminum alloy integrated electric drive assembly installation frame and low-pressure casting method thereof Download PDFInfo
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- CN111549263B CN111549263B CN202010508188.6A CN202010508188A CN111549263B CN 111549263 B CN111549263 B CN 111549263B CN 202010508188 A CN202010508188 A CN 202010508188A CN 111549263 B CN111549263 B CN 111549263B
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
- C22C21/04—Modified aluminium-silicon alloys
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60K1/00—Arrangement or mounting of electrical propulsion units
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/02—Making non-ferrous alloys by melting
- C22C1/026—Alloys based on aluminium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/06—Making non-ferrous alloys with the use of special agents for refining or deoxidising
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
- C22F1/043—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent
Abstract
The invention discloses an aluminum alloy integrated electric drive assembly mounting frame and a low-pressure casting method thereof, wherein the aluminum alloy material comprises the following components in percentage by weight: 8.3 to 9.7 percent of Si, 0.8 to 1.5 percent of Cu, 0.25 to 0.65 percent of Mg, 0.15 to 0.55 percent of Mn, 0.10 to 0.20 percent of Ti, less than or equal to 0.2 percent of Fe, less than or equal to 0.15 percent of Zn, and the balance of Al. The low-pressure casting method comprises the following steps: A. smelting, refining and refining the aluminum alloy material; B. preparing a mould, C, casting at low pressure, D, carrying out heat treatment and machining on the obtained casting. The aluminum alloy material does not need to be added with rare earth element RE and is cast at low pressure by a metal casting mold, so that the tensile strength of the casting is more than 335MPa, the yield strength is more than 305MPa, the elongation is more than 2.5%, the hardness is more than HB118, and the mechanical property is excellent.
Description
Technical Field
The invention relates to aluminum alloy casting, in particular to an aluminum alloy integrated electric drive assembly mounting frame and a low-pressure casting method thereof.
Background
Under the pressure of problems such as energy crisis, environmental pollution and global warming, the development of automobile parts in a direction of light weight is urgently needed. The aluminum alloy is the most applied light material in the current automobile materials, and the aluminum alloy materials for the automobile mainly comprise cast aluminum alloy and wrought aluminum alloy. Cast aluminum alloys are mainly used for engines, housings and chassis parts, and are the main form of aluminum alloys for automobiles.
The bearing type bracket assembly is mostly produced by adopting a high-strength steel plate punching and welding method. The bracket assembly produced by the punching and welding method has a large number of parts, needs to be formed by multiple processes of punching and welding, and has high manufacturing cost. If the bracket assembly is developed by adopting high-performance aluminum alloy and a low-pressure casting method, the number of parts of the whole automobile can be reduced, the manufacturing process of the parts is simplified, and the development of light weight of the parts of the automobile is promoted on the premise of meeting the functional requirements and various performances of the product.
The Chinese patent with publication number CN106925756A discloses a low-pressure casting preparation method of an aluminum alloy auxiliary frame, wherein the weight percentages of the materials are as follows: 6.5-7.5% of Si, 0.25-0.6% of Mg, 0.05-0.30% of Ti, 0-0.5% of RE, Fe0.2% of max, Cu0.2% of max, Mn0.1% of max, Zn0.1% of max and the balance of aluminum, wherein the tensile strength of the material after low-pressure casting is greater than 264MPa, the yield strength is greater than 210MPa, the elongation is greater than 2%, and the hardness is greater than HB 96. The RE material is needed to be used for the material, the cost is high, and the mechanical property index of the material is insufficient, so that the preparation requirement of the integrated electric drive assembly mounting frame cannot be met.
The parts that electric drive assembly installation frame need carry are the important part of new energy automobile's actuating system, and the frame is fixed on the automobile body through three suspension, and the parts that carry on the frame are total big, according to simulation analysis result, combines operating condition, confirms that the yield strength of frame needs to be greater than 235Mpa, and the product adopts the welding piece earlier stage, exists from heavy, the process is many, manufacturing cycle is long and the high shortcoming of price.
Therefore, it is necessary to develop an aluminum alloy integrated electric drive assembly mounting frame with low cost and excellent mechanical properties and a low-pressure casting method thereof.
Disclosure of Invention
The invention aims to solve the defects of the background technology and provide an aluminum alloy integrated electric drive assembly mounting frame with low cost and excellent mechanical property and a low-pressure casting method thereof.
The technical scheme of the invention is as follows: the utility model provides an aluminum alloy integrated form electric drive assembly installation frame which characterized in that, used aluminum alloy material includes each following composition by weight percent:
8.3 to 9.7 percent of Si, 0.8 to 1.5 percent of Cu, 0.25 to 0.65 percent of Mg, 0.15 to 0.55 percent of Mn, 0.10 to 0.20 percent of Ti, less than or equal to 0.2 percent of Fe, less than or equal to 0.15 percent of Zn, and the balance of Al. In the aluminum alloy material, both Fe and Zn are inevitable impurities, so that the maximum content of Fe is not more than 0.2 percent and the maximum content of Zn is not more than 0.15 percent.
Preferably, the aluminum alloy material comprises the following components in percentage by weight:
8.4 to 9.2 percent of Si, 1.0 to 1.4 percent of Cu, 0.25 to 0.65 percent of Mg, 0.15 to 0.55 percent of Mn, 0.10 to 0.20 percent of Ti, less than or equal to 0.2 percent of Fe, less than or equal to 0.15 percent of Zn, and the balance of Al.
The invention also provides a low-pressure casting method of the aluminum alloy integrated electric drive assembly mounting frame, which is characterized by comprising the following steps of:
A. smelting, refining and refining the aluminum alloy material;
B. preparing a die: carrying out sand blasting treatment on the surface of a cavity of the metal module, heating to 230-250 ℃, spraying a primer and sintering, after sintering, continuously spraying a surface coating on the surface of the cavity, wherein the surface coating is sprayed in two times, the first spraying thickness is 20-40 mu m, when the temperature of the surface of the cavity is reduced to 160-180 ℃, the second spraying is carried out, the total spraying thickness of the two times is 40-200 mu m, and the metal module is cooled and assembled to form a whole mold and is preheated for later use;
C. injecting the aluminum alloy material obtained in the step A into the die prepared in the step B for low-pressure casting;
D. and carrying out heat treatment and machining on the obtained casting to obtain the integrated electric drive assembly mounting frame.
Preferably, the step A of smelting, refining and refining the aluminum alloy material comprises the following processes: the raw materials are put into a gas melting furnace according to the proportion for heating and melting, the aluminum alloy liquid is transferred into a preheated transfer ladle when the temperature of the aluminum alloy liquid rises to 760-.
Further, the step B mold is prepared as follows: performing sand blasting treatment on the surface of a cavity of a metal module, then placing the metal module into a trolley type resistance furnace to heat to 230-; taking out the metal module and continuing to spray the surface layer coating on the surface of the cavity, wherein the surface layer coating is sprayed for two times, the first spraying thickness is 20-40 mu m, when the temperature of the surface of the mold is reduced to 160-180 ℃, the second spraying is carried out, and the total thickness of the two spraying is 40-200 mu m;
and (3) after the metal modules are cooled to normal temperature, assembling the metal modules into a whole die, fixing the assembled die on an upper bottom plate and a lower bottom plate of a low-pressure casting machine, preheating the surface of a die cavity of the die by adopting natural gas, and performing die assembly for later use when the preheating temperature reaches 350-400 ℃.
Further, the low-pressure casting in step C includes the following processes:
the aluminum alloy material is poured at the temperature of 700-.
Further, the heat treatment in step D includes the following processes: and carrying out solid solution and complete artificial aging heat treatment on the casting, wherein the temperature of the solid solution heat treatment is 500-510 ℃, the time is 4-6h, the quenching temperature is 75-85 ℃, the time is 4-6min, and the temperature of the aging heat treatment is 170-180 ℃, and the time is 5-8 h.
The invention has the beneficial effects that:
1. rare earth element RE is not required to be added, the content of silicon Si element is higher than about 2 percent (the average value of upper and lower limits of the element) in the prior art, the content of copper Cu element is about 1.2 percent, the content of manganese Mn element is about 0.25 percent, Mg and Cu are added into Al-Si alloy, and various compounds Mg can be formed in the alloy2Si、CuAl2And quaternary phase W (Al)xMg5Cu4Si4) The compounds are all strengthening phases in the aluminum alloy, wherein the heat treatment strengthening effect of the W phase is the best, and Mg2Si is the second, and the heat strength is CuAl2Most preferably. The addition of Mn in the alloy not only has the effect of solid solution strengthening, but also can change the shape of a needle-shaped iron-rich phase to form a skeleton-shaped AlFeMnSi phase, thereby improving the shaping of the alloy. The existence of these phases in the alloy can be deposited and hardened after heat treatment, which greatly helps to improve the mechanical properties, especially the tensile strength and yield strength, so that the part can bear heavy load. The tensile strength of the casting is larger than 335MPa, the yield strength is larger than 305MPa, the elongation is larger than 2.5%, the hardness is larger than HB118, and the mechanical property is greatly improved.
2. Compared with the resin sand mold casting mold in the prior art, the obtained casting has small dimensional tolerance and small surface roughness, the metal casting mold is suitable for mass production, and the service life of the metal casting mold can generally reach 5-8 ten thousand. Because of the chilling effect of the metal mold, under the same low-pressure casting process condition, the mechanical property of the casting produced by the metal mold is greatly improved compared with that produced by a sand mold, the tensile strength is improved by 15% compared with that produced by sand mold casting, the specific principle is that the thermal conductivity and thermal capacity of the metal mold are large, the cooling speed of the casting is high, the structure of the casting is compact, and the structure determines the performance, so that the Brinell hardness HBS can be improved to a certain extent while the tensile strength is increased.
3. Compared with the existing multi-part welded electric drive assembly mounting frame, the integral aluminum alloy electric drive assembly mounting frame prepared by the invention reduces the parts of the whole vehicle, lightens the whole vehicle, and widens the application condition due to good mechanical property.
Drawings
FIG. 1 is a picture of a mounting frame of an electric drive assembly according to the present invention (top view)
FIG. 2 is a picture of a mounting frame of an electric drive assembly made in accordance with the present invention (bottom view)
FIG. 3 is an X-ray photograph of a portion of the mounting frame (a) of the electric drive assembly of FIG. 1
FIG. 4 is an X-ray photograph of a portion of the mounting frame (b) of the electric drive assembly of FIG. 1
FIG. 5 is an X-ray photograph of a portion of the mounting frame (c) of the electric drive assembly of FIG. 2
FIG. 6 is an X-ray photograph of portions of the mounting frame (d), (e) of the electric drive assembly of FIG. 2
Detailed Description
The invention is described in further detail below with reference to the figures and the specific embodiments.
Example 1
The invention provides an aluminum alloy integrated electric drive assembly mounting frame, which comprises the following components in percentage by weight: si: 8.4%, Cu: 1.4%, Mg: 0.65%, Mn: 0.55%, Ti: 0.20 percent, less than or equal to 0.2 percent of Fe, less than or equal to 0.15 percent of Zn, and the balance of Al.
The low-pressure casting method of the aluminum alloy material comprises the following steps:
A. smelting, refining and refining the aluminum alloy material: the raw materials are put into a gas melting furnace according to the component ratio, heated and melted, the aluminum alloy liquid is transferred into a preheated transfer ladle when the temperature of the aluminum alloy liquid is raised to 760 ℃, the alloy liquid is adjusted to 720 ℃, then AlSr10 alterant and AlTi5B1 refiner are added, argon is introduced for refining and degassing treatment, the refining and degassing treatment time is 9min, and slag is removed after the refining is finished with the gas flow of 19 LPM. And standing the aluminum alloy liquid, cooling to 700 ℃, transferring to a low-pressure casting machine holding furnace, and waiting for casting.
B. Preparing a die: the surface of a cavity of a metal module is subjected to sand blasting treatment, the metal module is placed into a trolley type resistance furnace to be heated to 230 ℃, the module is taken out, primer (DR87, product of Fuji Kerr Co., Ltd.) is sprayed on the surface of the cavity, the thickness of the primer is 10 mu m, and after spraying is finished, the metal module is sent into the resistance furnace to be sintered, the sintering temperature is 200 ℃, and the sintering time is 1 hour. And then taking out the module to spray surface layer coating (D34, a product of Fuji Kelvin) on the surface of the cavity, wherein the surface layer coating is sprayed for two times, the first spraying thickness is 20-40 mu m, the second spraying is carried out when the temperature of the surface of the die is reduced to 180 ℃, and the second spraying thickness is used for spraying each part according to the requirements of an operation instruction, and the total range is 40-200 mu m. And after the module is cooled, assembling the die. And (3) fixing the assembled die on an upper bottom plate and a lower bottom plate of a low-pressure casting machine, preheating the surface of a die cavity of the die by adopting natural gas, and closing the die for later use when the preheating temperature reaches 350 ℃.
C. And (3) injecting the aluminum alloy material obtained in the step A into the die prepared in the step B for low-pressure casting: the pouring temperature of the aluminum alloy is 700 ℃, the pouring process is carried out in four stages, the pressure of the first stage is 230mbar (millibar), the time is 15s, the pressure of the second stage is 280mbar, the time is 7s, the pressure of the third stage is 320mbar, the time is 4s, the pressure of the fourth stage is 400mbar, the time is 4s, the pressure maintaining time under the pressure of the fourth stage is 100s, and after pressure relief, the casting is cooled in a mold for 240 s. And after the molding is finished, opening the mold to take out the casting, and checking the appearance quality and the surface defects of the casting. The product percent of pass reaches more than 95 percent.
D. And carrying out heat treatment and machining on the obtained casting to obtain the integrated electric drive assembly mounting frame, wherein the solution heat treatment temperature and time are 510 ℃ multiplied by 6h, the quenching temperature and time are 85 ℃ multiplied by 6min, and the aging heat treatment temperature and time are 180 ℃ multiplied by 5 h.
The product prepared by the embodiment is sampled and tested for mechanical properties, and has tensile strength of more than 335MPa, yield strength of more than 305MPa, elongation of more than 2.5 percent and hardness of more than HB 118.
Example 2
The invention provides an aluminum alloy integrated electric drive assembly mounting frame, which comprises the following components in percentage by weight: si: 9.2%, Cu: 1%, Mg: 0.55%, Mn: 0.45%, Ti: 0.18 percent, less than or equal to 0.2 percent of Fe, less than or equal to 0.15 percent of Zn, and the balance of Al.
The low-pressure casting method of the aluminum alloy material comprises the following steps:
A. smelting, refining and refining the aluminum alloy material: the raw materials are put into a gas melting furnace according to the component ratio, heated and melted, the aluminum alloy liquid is transferred into a preheated transfer ladle when the temperature of the aluminum alloy liquid rises to 765 ℃, the temperature of the alloy liquid is adjusted to 725 ℃, AlSr10 alterant and AlTi5B1 refiner are added, argon is introduced for refining degassing treatment, the refining degassing treatment time is 10min, the gas flow is 19LPM, slag is removed after refining, and the density equivalent of an aluminum sample is sampled and detected. And standing the aluminum alloy liquid, cooling to 705 ℃, transferring to a holding furnace of a low-pressure casting machine, and waiting for casting.
B. Preparing a die: and (2) carrying out sand blasting treatment on the surface of the cavity of the metal module, then placing the metal module into a trolley type resistance furnace to heat to 240 ℃, taking out the metal module, spraying primer (DR87) on the surface of the cavity, wherein the thickness of the primer is 12 mu m, after spraying is finished, sending the metal module into the resistance furnace to carry out coating sintering, wherein the sintering temperature is 210 ℃, and the sintering time is 1 hour. And then taking out the metal module, and spraying surface layer coating (D34) on the surface of the cavity, wherein the surface layer coating is sprayed for two times, the first spraying thickness is 20-40 mu m, when the surface temperature of the die is reduced to 170 ℃, the second spraying is carried out, and the second spraying thickness is used for spraying each part according to the requirements of an operation instruction, and the total range is 40-200 mu m. And (3) after the metal modules are cooled to normal temperature, assembling the metal modules into a whole die, fixing the assembled die on an upper bottom plate and a lower bottom plate of a low-pressure casting machine, preheating the surface of a die cavity of the die by adopting natural gas, and performing die assembly for later use when the preheating temperature reaches 360 ℃.
C. And (3) injecting the aluminum alloy material obtained in the step A into the die prepared in the step B for low-pressure casting: the pouring temperature of the aluminum alloy is 705 ℃, the pouring process is carried out in four stages, the pressure of the first stage is 232mbar (millibar), the time is 15s, the pressure of the second stage is 282mbar, the time is 7s, the pressure of the third stage is 322mbar, the time is 4s, the pressure of the fourth stage is 410mbar, the time is 4s, the pressure maintaining time under the pressure of the fourth stage is 100s, and after pressure relief, the casting is cooled in a mold for 240 s. And after the molding is finished, opening the mold to take out the casting, and checking the appearance quality and the surface defects of the casting. The product percent of pass reaches more than 95 percent.
D. And carrying out heat treatment and machining on the obtained casting to obtain the integrated electric drive assembly mounting frame, wherein the solution heat treatment temperature and time are 505 ℃ multiplied by 5.5h, the quenching temperature and time are 83 ℃ multiplied by 5min, and the aging heat treatment temperature and time are 172 ℃ multiplied by 8 h.
The product prepared by the embodiment is sampled and tested for mechanical properties, the tensile strength is greater than 330MPa, the yield strength is greater than 297MPa, the elongation is greater than 3%, and the hardness is greater than HB 110.
Example 3
The invention provides an aluminum alloy integrated electric drive assembly mounting frame, which comprises the following components in percentage by weight: si: 8.3%, Cu: 0.8%, Mg: 0.35%, Mn: 0.25%, Ti: 0.13 percent, less than or equal to 0.2 percent of Fe, less than or equal to 0.15 percent of Zn, and the balance of Al.
The low-pressure casting method of the aluminum alloy material comprises the following steps:
A. smelting, refining and refining the aluminum alloy material: the raw materials are put into a gas melting furnace according to the component ratio, heated and melted, when the temperature of the aluminum alloy liquid rises to 770 ℃, the aluminum alloy liquid is transferred into a preheated transfer ladle, the temperature of the alloy liquid is adjusted to 730 ℃, AlSr10 alterant and AlTi5B1 refiner are added, argon is introduced for refining degassing treatment, the refining degassing treatment time is 10min, the gas flow is 20LPM, slag is removed after refining, and the density equivalent of an aluminum sample is sampled and detected. And standing the aluminum alloy liquid, cooling to 710 ℃, transferring to a low-pressure casting machine holding furnace, and waiting for casting.
B. Preparing a die: and (2) carrying out sand blasting treatment on the surface of the cavity of the metal module, then placing the metal module into a trolley type resistance furnace to heat to 245 ℃, taking out the metal module, spraying primer (DR87) on the surface of the cavity, wherein the thickness of the primer is 12 mu m, after spraying is finished, sending the metal module into the resistance furnace to carry out coating sintering, wherein the sintering temperature is 220 ℃, and the sintering time is 1 hour. And then taking out the metal module, and spraying surface layer coating (D34) on the surface of the cavity, wherein the surface layer coating is sprayed for two times, the first spraying thickness is 20-40 mu m, when the surface temperature of the die is reduced to 175 ℃, the second spraying is carried out, and the second spraying thickness is used for spraying each part according to the requirements of an operation instruction, and the total range is 40-200 mu m. And (3) after the metal modules are cooled to normal temperature, assembling the metal modules into a whole die, fixing the assembled die on an upper bottom plate and a lower bottom plate of a low-pressure casting machine, preheating the surface of a die cavity of the die by adopting natural gas, and performing die assembly for later use when the preheating temperature reaches 370 ℃.
C. And (3) injecting the aluminum alloy material obtained in the step A into the die prepared in the step B for low-pressure casting: the pouring temperature of the aluminum alloy is 705 ℃, the pouring process is carried out in four stages, the pressure of the first stage is 233mbar (millibar), the time is 15s, the pressure of the second stage is 283mbar, the time is 7s, the pressure of the third stage is 323mbar, the time is 4s, the pressure of the fourth stage is 420mbar, the time is 4s, the pressure maintaining time under the pressure of the fourth stage is 100s, and after pressure relief, the casting is cooled in a die for 240 s. And after the molding is finished, opening the mold to take out the casting, and checking the appearance quality and the surface defects of the casting. The product percent of pass reaches more than 95 percent.
D. And carrying out heat treatment and machining on the obtained casting to obtain the integrated electric drive assembly mounting frame, wherein the solution heat treatment temperature and time are 505 ℃ multiplied by 4.5h, the quenching temperature and time are 80 ℃ multiplied by 5min, and the aging heat treatment temperature and time are 173 ℃ multiplied by 7.5 h.
The product prepared by the embodiment is sampled and tested for mechanical properties, the tensile strength is more than 324MPa, the yield strength is more than 285MPa, the elongation is more than 3%, and the hardness is more than HB 108.
Example 4
The invention provides an aluminum alloy integrated electric drive assembly mounting frame, which comprises the following components in percentage by weight: si: 9.7%, Cu: 1.5%, Mg: 0.25%, Mn: 0.15%, Ti: 0.10 percent, less than or equal to 0.2 percent of Fe, less than or equal to 0.15 percent of Zn, and the balance of Al.
The low-pressure casting method of the aluminum alloy material comprises the following steps:
A. smelting, refining and refining the aluminum alloy material: the raw materials are put into a gas melting furnace according to the component ratio, heated and melted, the aluminum alloy liquid is transferred into a preheated transfer ladle when the temperature of the aluminum alloy liquid is increased to 770 ℃, the alloy liquid is adjusted to 735 ℃, then AlSr10 alterant and AlTi5B1 refiner are added, argon is introduced for refining degassing treatment, the refining degassing treatment time is 12min, the gas flow is 20LPM, slag is removed after refining, and the density equivalent of an aluminum sample is sampled and detected. And standing the aluminum alloy liquid, cooling to 715 ℃, transferring to a low-pressure casting machine holding furnace, and waiting for casting.
B. Preparing a die: and (2) carrying out sand blasting treatment on the surface of the cavity of the metal module, then placing the metal module into a trolley type resistance furnace to heat to 245 ℃, taking out the metal module, spraying primer (DR87) on the surface of the cavity, wherein the thickness of the primer is 15 mu m, after spraying is finished, sending the metal module into the resistance furnace to carry out coating sintering, wherein the sintering temperature is 230 ℃, and the sintering time is 1 hour. And then taking out the metal module, and spraying surface layer coating (D34) on the surface of the cavity, wherein the surface layer coating is sprayed for two times, the first spraying thickness is 20-40 mu m, when the surface temperature of the die is reduced to 175 ℃, the second spraying is carried out, and the second spraying thickness is used for spraying each part according to the requirements of an operation instruction, and the total range is 40-200 mu m. And (3) after the metal modules are cooled to normal temperature, assembling the metal modules into a whole die, fixing the assembled die on an upper bottom plate and a lower bottom plate of a low-pressure casting machine, preheating the surface of a die cavity of the die by adopting natural gas, and performing die assembly for later use when the preheating temperature reaches 390 ℃.
C. And (3) injecting the aluminum alloy material obtained in the step A into the die prepared in the step B for low-pressure casting: the pouring temperature of the aluminum alloy is 705 ℃, the pouring process is carried out in four stages, the pressure of the first stage is 234mbar (millibar), the time is 15s, the pressure of the second stage is 284mbar, the time is 7s, the pressure of the third stage is 324mbar, the time is 4s, the pressure of the fourth stage is 440mbar, the time is 4s, the pressure maintaining time under the pressure of the fourth stage is 100s, and after pressure relief, the casting is cooled in a mold for 240 s. And after the molding is finished, opening the mold to take out the casting, and checking the appearance quality and the surface defects of the casting. The product percent of pass reaches more than 95 percent.
D. And carrying out heat treatment and machining on the obtained casting to obtain the integrated electric drive assembly mounting frame, wherein the solution heat treatment temperature and time are 505 ℃ multiplied by 5h, the quenching temperature and time are 78 ℃ multiplied by 4.5min, and the aging heat treatment temperature and time are 170 ℃ multiplied by 6.5 h.
The body is sampled for mechanical property detection, the tensile strength is more than 332MPa, the yield strength is more than 303MPa, the elongation is more than 2.5 percent, and the hardness is more than HB 116.
Example 5
The invention provides an aluminum alloy integrated electric drive assembly mounting frame, which comprises the following components in percentage by weight: si: 9.0%, Cu: 1.15%, Mg: 0.45%, Mn: 0.35%, Ti: 0.15 percent, less than or equal to 0.2 percent of Fe, less than or equal to 0.15 percent of Zn, and the balance of Al.
The low-pressure casting method of the aluminum alloy material comprises the following steps:
A. smelting, refining and refining the aluminum alloy material: the raw materials are put into a gas melting furnace according to the component ratio, heated and melted, when the temperature of the aluminum alloy liquid rises to 780 ℃, the aluminum alloy liquid is transferred into a preheated transfer ladle, the temperature of the alloy liquid is adjusted to 740 ℃, AlSr10 alterant and AlTi5B1 refiner are added, argon is introduced for refining degassing treatment, the refining degassing treatment time is 12min, the gas flow is 20LPM, slag is removed after refining, and the density equivalent of an aluminum sample is sampled and detected. And standing the aluminum alloy liquid, cooling to 720 ℃, transferring to a low-pressure casting machine holding furnace, and waiting for casting.
B. Preparing a die: and (2) carrying out sand blasting treatment on the surface of the cavity of the metal module, then placing the metal module into a trolley type resistance furnace to heat the metal module to 250 ℃, taking out the metal module, spraying primer (DR87) on the surface of the cavity, wherein the thickness of the primer is 15 mu m, after spraying is finished, sending the metal module into the resistance furnace to carry out coating sintering, wherein the sintering temperature is 240 ℃, and the sintering time is 1 hour. And then taking out the metal module, and spraying surface layer coating (D34) on the surface of the cavity, wherein the surface layer coating is sprayed for two times, the first spraying thickness is 20-40 mu m, when the temperature of the surface of the die is reduced to 160 ℃, the second spraying is carried out, and the second spraying thickness is used for spraying each part according to the requirements of an operation instruction, and the total range is 40-200 mu m. And (3) after the metal modules are cooled to normal temperature, assembling the metal modules into a whole die, fixing the assembled die on an upper bottom plate and a lower bottom plate of a low-pressure casting machine, preheating the surface of a die cavity of the die by adopting natural gas, and performing die assembly for later use when the preheating temperature reaches 400 ℃.
C. And (3) injecting the aluminum alloy material obtained in the step A into the die prepared in the step B for low-pressure casting: the pouring temperature of the aluminum alloy is 710 ℃, the pouring process is carried out in four stages, the pressure of the first stage is 235mbar (millibar), the time is 15s, the pressure of the second stage is 285mbar, the time is 7s, the pressure of the third stage is 325mbar, the time is 4s, the pressure of the fourth stage is 450mbar, the time is 4s, the pressure maintaining time under the pressure of the fourth stage is 100s, and after pressure relief, the casting is cooled in a mold for 240 s. And after the molding is finished, opening the mold to take out the casting, and checking the appearance quality and the surface defects of the casting. The product percent of pass reaches more than 95 percent.
D. And carrying out heat treatment and machining on the obtained casting to obtain the integrated electric drive assembly mounting frame, wherein the solution heat treatment temperature and time are 500 ℃ multiplied by 4h, the quenching temperature and time are 75 ℃ multiplied by 4min, and the aging heat treatment temperature and time are 170 ℃ multiplied by 6 h.
The product prepared by the embodiment is sampled and tested for mechanical properties, the tensile strength is greater than 320MPa, the yield strength is greater than 287MPa, the elongation is greater than 3%, and the hardness is greater than HB 107.
The mounting frame object of the electric drive assembly prepared by the invention is shown in figures 1-2, and the mechanical property detection results of the products in examples 1-5 are shown in table 1.
TABLE 1 test results of mechanical properties of products
| Item numbering | Tensile strength | Yield strength | Elongation percentage | Hardness of |
| Example 1 | ＞335MPa | ＞305MPa | ＞2.5％ | ＞HB118 |
| Example 2 | ＞330MPa | ＞297MPa | ＞3％ | ＞HB110 |
| Example 3 | ＞324MPa | ＞285MPa | ＞3％ | ＞HB108 |
| Example 4 | ＞332MPa | ＞303MPa | ＞2.5％ | ＞HB116 |
| Example 5 | ＞320MPa | ＞287MPa | ＞3％ | ＞HB107 |
| Prior Art | ＞264MPa | ＞210MPa | ＞2％ | ＞HB96 |
From the above table 1, after the low-pressure cast aluminum alloy electric drive assembly installation frame casting is subjected to heat treatment, the high comprehensive mechanical property is obtained, the aluminum alloy automobile casting is superior to the aluminum alloy automobile casting in the prior art, the appearance quality of the casting is good, as shown in fig. 3-6, the defects of no shrinkage porosity inclusion and the like in the casting are detected by X-ray, the internal structure is good, and the requirement of the aluminum alloy integrated electric drive assembly installation frame casting is met.
Claims (1)
1. The low-pressure casting method for the aluminum alloy integrated electric drive assembly mounting frame is characterized in that the aluminum alloy material used by the mounting frame comprises the following components in percentage by weight: 8.4 to 9.2 percent of Si, 1.0 to 1.4 percent of Cu, 0.25 to 0.65 percent of Mg, 0.15 to 0.25 percent of Mn, 0.10 to 0.20 percent of Ti, less than or equal to 0.2 percent of Fe, less than or equal to 0.15 percent of Zn, and the balance of Al;
the low-pressure casting method of the mounting frame comprises the following steps:
A. the prepared aluminum alloy material is smelted, refined and refined, and the method comprises the following steps: putting the raw materials into a gas melting furnace according to the proportion, heating and melting, transferring the aluminum alloy liquid into a preheated transfer ladle when the temperature of the aluminum alloy liquid rises to 760-;
B. preparing a die: performing sand blasting treatment on the surface of a cavity of a metal module, then placing the metal module into a trolley type resistance furnace to heat to 230-; taking out the metal module and continuing to spray the surface layer coating on the surface of the cavity, wherein the surface layer coating is sprayed for two times, the first spraying thickness is 20-40 mu m, when the temperature of the surface of the mold is reduced to 160-180 ℃, the second spraying is carried out, and the total thickness of the two spraying is 40-200 mu m;
after the metal modules are cooled to normal temperature, assembling the metal modules into a whole die, fixing the assembled die on an upper bottom plate and a lower bottom plate of a low-pressure casting machine, preheating the surface of a die cavity of the die by adopting natural gas, and performing die assembly for later use when the preheating temperature reaches 350-400 ℃;
C. and C, injecting the aluminum alloy material obtained by the treatment in the step A into the die prepared in the step B for low-pressure casting, wherein the low-pressure casting comprises the following processes:
pouring the aluminum alloy material at the temperature of 700-;
D. carrying out heat treatment and machining on the obtained casting, wherein the heat treatment comprises the following processes: carrying out solid solution and complete artificial aging heat treatment on the casting, wherein the temperature of the solid solution heat treatment is 500-510 ℃, the time is 4-6h, the quenching temperature is 75-85 ℃, the time is 4-6min, the temperature of the aging heat treatment is 170-180 ℃, and the time is 5-8 h; an integrated electric drive assembly mounting frame is obtained.
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| CN102806320A (en) * | 2011-05-31 | 2012-12-05 | 旭技术株式会社 | Coating method |
| JP2016132787A (en) * | 2015-01-16 | 2016-07-25 | 日立金属株式会社 | Method for manufacturing load wheel made of aluminum alloy |
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| CN102806320A (en) * | 2011-05-31 | 2012-12-05 | 旭技术株式会社 | Coating method |
| CN105874090A (en) * | 2013-12-20 | 2016-08-17 | 美铝公司 | High performance alsimgcu casting alloy |
| JP2016132787A (en) * | 2015-01-16 | 2016-07-25 | 日立金属株式会社 | Method for manufacturing load wheel made of aluminum alloy |
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