Product Development of Alternative Alloy Wheel Material with Improved Mechanical Properties


Özaydın O., Dikicioğlu A.

International Journal of Metalcasting, 2022 (SCI-Expanded) identifier

  • Publication Type: Article / Article
  • Publication Date: 2022
  • Doi Number: 10.1007/s40962-022-00914-6
  • Journal Name: International Journal of Metalcasting
  • Journal Indexes: Science Citation Index Expanded (SCI-EXPANDED), Scopus, Academic Search Premier, Aerospace Database, Communication Abstracts, Compendex, Metadex, Civil Engineering Abstracts
  • Keywords: 13° impact tests, aluminum alloy wheels, cornering fatigue tests, experimental solutions, numerical solutions
  • Istanbul Technical University Affiliated: Yes

Abstract

© 2022, American Foundry Society.AlSi7Mg and AlSi11Mg alloys are common materials for the aluminum alloy wheels production with LPDC (Low-Pressure Die Casting) method. The biggest difference between these two main materials is heat treatment process. T6 (Solution–Quenching–Artificial aging) heat treatment process is applied to all AlSi7Mg alloy wheels. On the other side, there is no heat treatment process applied to AlSi11Mg alloy wheels. In this study, alternative aluminum alloy which has different silicon ranges between AlSi7Mg and AlSi11Mg is studied. In addition to this, the development studies such as grain refinement studies, modification studies and heat treatment studies on this alternative alloy improve the mechanical properties. All these development studies are applied to related alternative aluminum alloy wheels to improve mechanical properties such as ultimate tensile strength and yield strength. Design and product validation processes are applied to all cast aluminum alloy wheels. In the design validation process using numerical method, cornering fatigue test simulation and 13° impact test simulation using Ansys Workbench and Ansys LS-Dyna software are validated. In the product validation process using numerical method, casting simulation of wheels using MagmaSoft—MagmaWheel software is validated. After the validation of design and product numerical method, validation of design and product with experimental method is proceeded as a next step. In the design validation using experimental method, cornering fatigue test and 13° impact test of alternative aluminum alloy wheels using special test machines are validated. In the product validation process using experimental method, casting process of alternative aluminum alloy wheels with LPDC machine is validated. In the heat treatment process, various heat treatment temperatures (165–180 °C) and various heat treatment application times (2 h–4 h–6 h) are applied to wheels. In the analysis phase, ultimate tensile strength and yield strength are increased with higher heat treatment temperature and longer heat treatment time. Oppositely, elongation is decreased with higher heat treatment temperature and longer heat treatment time. Different heat treatment temperatures and heat treatment application time on the alternative aluminum alloy wheels may be arranged to increase the mechanical properties such as ultimate tensile strength and yield strength or elongation. According to all simulations and results in this study, the alternative aluminum alloy for the wheels is evaluated as ‘approved’ for the related project. Development studies such as ‘grain refinement studies,’ ‘modification studies’ and ‘heat treatment studies’ may be applied to alternative aluminum alloy to improve mechanical properties.