Application of ultrasonic vibration to shape-casting based on resonance vibration analysis

The application of ultrasonic vibration during the casting process has been proven to refine the microstructure and enhance the properties of the casting. By using the direct inserting method, wherein the ultrasonic horn is inserted directly into the melt, ultrasonic treatment can be utilized in the semi-continuous casting process to produce aluminum ingots with simple shapes. However, due to the attenuation of ultrasound, it is challenging to apply the direct inserting method in the die casting process to produce complex castings. Thus, in this study, the impact of ultrasonic vibration on the microstructure of a gravity die-cast AlSi 9 Cu 3 end cap was investigated by applying ultrasonic vibration on the core (indirect method). It is found that the effect of ultrasonic vibration relies greatly on the resonance mode of the core. Selection of ultrasonic vibration schemes mainly depends on the core structure, and only a strong vibration can significantly refine the microstructure of the casting. For castings with complex structures, an elaborated ultrasonic vibration design is necessary to refine the microstructure of the specified casting. In addition, strong vibration applied on the feeding channel can promote the feeding ability of casting by breaking the dendrites during solidification, and consequently reduce the shrinkage porosity.