Process optimization of A356 aluminum alloy wheel hub fabricated by low-pressure die casting with simulation and experimental coupling methods

The aluminum alloy wheel hub is mainly produced by low-pressure die casting process (LPDC), in which casting quality is closely related to the process parameters. In this paper, the LPDC process of the A356 alloy wheel hub was numerically simulated by ProCAST software, and the forming quality of the wheel hub under different cooling processes has been studied. The result indicated that the liquid aluminum exhibited different solidification characteristics under three cooling processes of 300 L/h for 150 s, 400 L/h for 140 s and 500 L/h for 130 s. A sequential solidification state was obtained under the condition of 400 L/h for 140 s. By comparing the tensile properties of the rim under different cooling processes, it was found that the wheel hub casted under 400 L/h for 140 s had higher tensile strength and elongation, which were 178.9 MPa and 6.6%, respectively. The reduction of casting defects, microstructure refinement, and uniform distribution of eutectic Si particles in the wheel hub are the main reasons for the improvement of mechanical properties.