1. Introduction
In recent years, with the rapid development of new energy vehicles, the demand for high-quality aluminium alloy battery end plates has increased significantly. Low pressure casting is a widely used method for manufacturing these end plates due to its advantages such as good surface quality, dense microstructure, and excellent mechanical properties. However, the quality of the castings is highly dependent on various process parameters. Therefore, it is crucial to optimize these parameters to ensure the production of high-quality battery end plates.
1.1 Background of New Energy Vehicles
New energy vehicles have become increasingly popular in recent years due to their environmental friendliness and energy efficiency. The development of new energy vehicles is an important measure to address the challenges of energy shortage and environmental pollution. Battery end plates play a crucial role in the performance and safety of the battery system in new energy vehicles.
1.2 Importance of Aluminium Alloy Battery End Plates
Aluminium alloy is widely used in battery end plates because of its excellent properties such as light weight, high strength, good corrosion resistance, and good thermal conductivity. The quality of the battery end plates directly affects the performance and lifespan of the battery system. Therefore, it is necessary to ensure the high quality of the aluminium alloy battery end plates through proper manufacturing processes.
1.3 Overview of Low Pressure Casting
Low pressure casting is a casting method that uses a low-pressure gas to force the molten metal into the mould cavity. It has the advantages of good fluidity of the molten metal, uniform filling of the mould cavity, and good quality of the castings. The process parameters of low pressure casting include casting temperature, mould preheating temperature, filling time, etc. These parameters have a significant impact on the quality of the castings.
2. Experimental Methods
In this study, an orthogonal experimental design and signal-to-noise ratio analysis were used to investigate the effects of process parameters on the quality of aluminium alloy battery end plates.
2.1 Orthogonal Experimental Design
An orthogonal experimental design was used to select a set of representative process parameter combinations. The factors considered in this study were casting temperature, mould preheating temperature, and filling time. Each factor was set at four levels, resulting in a total of 16 experimental runs.
| Level | Casting Temperature (C) | Mould Preheating Temperature (C) | Filling Time (s) |
|---|---|---|---|
| 1 | 690 | 330 | 8 |
| 2 | 700 | 340 | 10 |
| 3 | 710 | 350 | 12 |
| 4 | 720 | 360 | 14 |
2.2 Signal-to-Noise Ratio Analysis
The signal-to-noise ratio (S/N) was used as an evaluation index to measure the quality of the castings. The S/N ratio was calculated based on the shrinkage rate and shrinkage pore volume, solidification time, and secondary dendrite interval of the castings. A smaller S/N ratio indicates better quality of the castings.
3. Results and Discussion
The results of the orthogonal experimental design and signal-to-noise ratio analysis are presented and discussed in this section.
3.1 Effects of Process Parameters on Shrinkage Rate and Shrinkage Pore Volume
The results showed that the filling time had the most significant impact on the shrinkage rate and shrinkage pore volume, followed by the casting temperature and mould preheating temperature. The optimal combination of process parameters for minimizing the shrinkage rate and shrinkage pore volume was found to be a casting temperature of 690 C, a mould preheating temperature of 330 C, and a filling time of 8 s.
| Process Parameter | Impact on Shrinkage Rate and Shrinkage Pore Volume |
|---|---|
| Filling Time | Most significant |
| Casting Temperature | Second most significant |
| Mould Preheating Temperature | Least significant |
3.2 Effects of Process Parameters on Solidification Time
The results showed that the mould preheating temperature had the most significant impact on the solidification time, followed by the casting temperature and filling time. The optimal combination of process parameters for minimizing the solidification time was found to be a casting temperature of 690 C, a mould preheating temperature of 330 C, and a filling time of 8 s.
| Process Parameter | Impact on Solidification Time |
|---|---|
| Mould Preheating Temperature | Most significant |
| Casting Temperature | Second most significant |
| Filling Time | Least significant |
3.3 Effects of Process Parameters on Secondary Dendrite Interval
The results showed that the mould preheating temperature had the most significant impact on the secondary dendrite interval, followed by the filling time and casting temperature. The optimal combination of process parameters for minimizing the secondary dendrite interval was found to be a casting temperature of 690 C, a mould preheating temperature of 330 C, and a filling time of 8 s.
| Process Parameter | Impact on Secondary Dendrite Interval |
|---|---|
| Mould Preheating Temperature | Most significant |
| Filling Time | Second most significant |
| Casting Temperature | Least significant |
3.4 Overall Optimal Process Parameters
Based on the above analysis, the overall optimal process parameters for aluminium alloy battery end plates were determined to be a casting temperature of 690 C, a mould preheating temperature of 330 C, and a filling time of 8 s. These parameters resulted in no shrinkage or shrinkage of the castings, the smallest secondary dendrite spacing, and the shortest solidification time.
4. Verification of Optimal Process Parameters
To verify the effectiveness of the optimal process parameters, numerical simulations and experimental tests were carried out.
4.1 Numerical Simulations
Numerical simulations were carried out using the ProCAST software to predict the quality of the castings under the optimal process parameters. The results of the numerical simulations showed that the castings had no shrinkage or shrinkage of the castings, the smallest secondary dendrite spacing, and the shortest solidification time, which were consistent with the theoretical predictions.
4.2 Experimental Tests
Experimental tests were carried out to verify the quality of the castings under the optimal process parameters. The castings were produced using the optimal process parameters, and samples were taken for metallographic analysis. The results of the metallographic analysis showed that the castings had a uniform microstructure, no obvious shrinkage or shrinkage of the castings, and a small secondary dendrite spacing, which were consistent with the numerical simulations and theoretical predictions.
5. Conclusions
In this study, an orthogonal experimental design and signal-to-noise ratio analysis were used to investigate the effects of process parameters on the quality of aluminium alloy battery end plates. The following conclusions were drawn:
5.1 Effects of Process Parameters
The filling time had the most significant impact on the shrinkage rate and shrinkage pore volume, while the mould preheating temperature had the most significant impact on the solidification time and secondary dendrite interval. The casting temperature also had an impact on these quality indicators.
5.2 Optimal Process Parameters
The overall optimal process parameters for aluminium alloy battery end plates were determined to be a casting temperature of 690 C, a mould preheating temperature of 330 C, and a filling time of 8 s. These parameters resulted in no shrinkage or shrinkage of the castings, the smallest secondary dendrite spacing, and the shortest solidification time.
5.3 Verification of Optimal Process Parameters
The optimal process parameters were verified through numerical simulations and experimental tests. The results showed that the castings had a uniform microstructure, no obvious shrinkage or shrinkage of the castings, and a small secondary dendrite spacing, which were consistent with the theoretical predictions.
This study provides a set of standardized process design parameters for the low-pressure casting of aluminium alloy battery end plates, which can be used as a reference for the production of high-quality battery end plates. Future studies can focus on further optimizing the process parameters and exploring other factors that may affect the quality of the castings.
6. Significance and Applications of the Research
6.1 Significance in the Field of New Energy Vehicles
The research on the optimization of low pressure casting process parameters for aluminium alloy battery end plates is of great significance in the field of new energy vehicles. High-quality battery end plates are crucial for the performance and safety of the battery system. By optimizing the process parameters, the quality of the end plates can be improved, which in turn can enhance the overall performance and lifespan of the battery system. This can contribute to the development and popularization of new energy vehicles.
6.2 Applications in Industrial Production
The standardized process design parameters obtained from this research can be directly applied in industrial production. Manufacturers can use these parameters to produce high-quality aluminium alloy battery end plates with consistent quality. This can help to reduce production costs, improve production efficiency, and meet the increasing market demand for high-quality battery end plates.
7. Future Research Directions
7.1 Optimization of Other Process Parameters
Although this study has focused on the optimization of casting temperature, mould preheating temperature, and filling time, there are other process parameters that may also affect the quality of the castings. Future research can explore the optimization of other parameters such as pressure control during the casting process, cooling rate of the mould, and the use of additives in the molten metal.
7.2 Investigation of the Effects of Different Alloys
This study has focused on the A356 aluminium alloy. However, different alloys may have different properties and may respond differently to the process parameters. Future research can investigate the effects of different alloys on the quality of the castings and explore the optimal process parameters for different alloys.
7.3 Integration of Advanced Technologies
With the development of advanced technologies such as artificial intelligence and machine learning, there is an opportunity to integrate these technologies into the casting process. Future research can explore the use of these technologies to predict and optimize the process parameters in real-time, which can further improve the quality of the castings.
8. Comparison with Other Casting Methods
8.1 Comparison with High Pressure Casting
High pressure casting is another commonly used casting method. Compared with high pressure casting, low pressure casting has the advantages of better fluidity of the molten metal, more uniform filling of the mould cavity, and less internal stress in the castings. However, high pressure casting may have a higher production rate in some cases. The choice between low pressure casting and high pressure casting depends on the specific requirements of the product.
8.2 Comparison with Gravity Casting
Gravity casting is a traditional casting method. Compared with gravity casting, low pressure casting has the advantages of better control of the filling process, better quality of the castings, and less porosity in the castings. Gravity casting may be more suitable for some simple products with low quality requirements.
9. Challenges and Solutions in the Application of the Research
9.1 Challenges in Industrial Implementation
In the industrial implementation of the research results, there may be challenges such as difficulty in accurately controlling the process parameters, variability in the quality of raw materials, and the need for significant investment in equipment and technology. These challenges can affect the reproducibility and consistency of the production process.
9.2 Solutions to Overcome the Challenges
To overcome these challenges, manufacturers can invest in advanced equipment and technology to improve the accuracy of process parameter control. They can also establish strict quality control systems for raw materials to ensure the consistency of the quality of the end plates. Additionally, continuous training and education for workers can help to improve their understanding and operation of the casting process.
10. Summary
This study has investigated the design and optimization of low pressure casting process parameters for aluminium alloy battery end plates. Through orthogonal experimental design and signal-to-noise ratio analysis, the optimal process parameters have been determined, and their effectiveness has been verified through numerical simulations and experimental tests. The research has significant implications for the field of new energy vehicles and industrial production. Future research directions have also been identified to further improve the quality of the castings. Although there are challenges in the application of the research, solutions have been proposed to overcome them. Overall, this study provides a valuable contribution to the development of high-quality aluminium alloy battery end plates.