Simulation and optimization of the casting process for a new commercial Al-4Cu-0.3Mg-0.25Mn-0.05Ag alloy cylinder head

作者：Fei Li, Zhongxi Yang, Junbao Guo, Zheng Li, Zhijun Ma, Long Bai · 发表于：Journal of Materials Research and Technology · 年份：2025 · DOI：10.1016/j.jmrt.2025.08.008 · 被引用次数：2 · 研究领域：Aluminum Alloy Microstructure Properties、Metallurgy and Material Forming、Aluminum Alloys Composites Properties

The cylinder head have a complex internal structure and significant variation in wall thickness. Consequently, the corresponding casting process poses challenges in design. In this study, casting simulation software was employed to assist in the design of the cylinder head casting process. Firstly, the distribution characteristics of the thermal sections in the cylinder head were analyzed, and preliminary casting process was designed for simulation and practical verification. The results indicated that the flow field and porosity distribution in the preliminary design process met the requirements, but thermal cracking defects occurred in the fire face. Additional simulation research showed that the wall thickness of the cylinder head's fire face varied significantly, which made it impossible to replace the local liquid phase and caused an uneven distribution of stress. To address this issue, in the process improvement, the sealing of the valve seat ring in the cylinder head was implemented to create a flat surface on the fire face, aiming to improve the solidification sequence and eliminate shrinkage stress around areas such as the valve seat ring. Finally, the casting process was validated through practical implementation, followed by corresponding inspection and analysis.