Recent Developments of Rheo-Diecast Components for Transportation Markets

Abstract

Recent developments and applications of rheo-diecast components for transportation markets are described. The components have been produced using the SEED (Swirled Enthalpy Equilibrium Device) semi-solid process. The development process typically involves several steps, including (1) an evaluation (and modification) of the component design to ensure it is suitable for semi-solid die casting, (2) the use of flow and solidification simulation to optimize the layout of the gating system, and to ensure that the modified component design can be produced without filling turbulence and shrinkage porosity, (3) stress modeling to ensure that the redesigned component will meet performance targets, and (4) in-plant development of the optimum process parameters. This development process will be described in detail for several commercial components, including two brackets for trucking applications, and connectors used in the frame of an electric bus.