Study on Squeeze Casting Process of the Integrated Aluminum Alloy Subframe

The subframe is a crucial load-bearing part of the chassis, playing a significant role in ensuring the safety and reliability of the vehicle. In this study, we aim to investigate the squeeze casting process of an integrated aluminum alloy subframe. Using relevant design criteria and casting theory, we have determined the optimal squeeze casting process for the whole subframe. The experimental factors for the subframe squeeze casting include pouring temperature, die temperature, filling velocity, and pressure holding time, while the response indexes are porosity, secondary dendrite arm spacing, and solidification time. These criteria were chosen based on their importance in determining the quality and mechanical properties of the casting. By studying the squeeze casting process of the integrated aluminum alloy subframe, we hope to improve the safety and reliability of chassis components. In this manuscript, the Box–Behnken design methodology was used to design the experiment scheme, and virtual casting simulation method is used to simulate the casting, and the input–output relationship model was developed. On this basis, the optimal process parameter combination was obtained by using the mayfly algorithm based on orthogonal and chaotic strategy (MAOLC). Simultaneously, the trial production test was carried out on the squeeze casting machine to verify the optimal parameters. X-ray inspection, metallographic structure testing, and mechanics performance testing show that the casting has no casting defects and has good mechanical properties.