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<p>Based on finite element simulation with commercial modeling software, this study employed a combined approach of numerical simulation and experimentation to optimize the casting process of a top core-pulling AlSi18 piston using ultrasonic vibration equipment. A self-designed ultrasonic vibration device was utilized to apply 24 kHz ultrasound to specific local areas of the piston during its solidification process. The research systematically investigated the practical effects of ultrasonic vibration on the solidification microstructure and feeding capacity of the engine aluminum alloy casting. The results demonstrate that ultrasonic vibration significantly enhances the feeding capacity of the casting through acoustic streaming effects and dendrite fragmentation mechanisms. Compared to castings produced without ultrasonic vibration, the aluminum piston treated with ultrasound exhibited noticeably refined grains. As the ultrasonic power increased, the vibration amplitude gradually rose, and the grain refinement effect initially strengthened and then weakened. The optimal grain refinement and the fewest defects were achieved at an ultrasonic power of 840 W.</p>

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Research on Ultrasonic-Assisted Casting Process for Aluminum Alloy Pistons

  • 期刊论文

  • 发表日期：

    2026年3月17日

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  • Xiaoyu Gu,
  • Bingtao Tang,
  • Zhiping Sun,
  • Zhiming Wang

摘要

Based on finite element simulation with commercial modeling software, this study employed a combined approach of numerical simulation and experimentation to optimize the casting process of a top core-pulling AlSi18 piston using ultrasonic vibration equipment. A self-designed ultrasonic vibration device was utilized to apply 24 kHz ultrasound to specific local areas of the piston during its solidification process. The research systematically investigated the practical effects of ultrasonic vibration on the solidification microstructure and feeding capacity of the engine aluminum alloy casting. The results demonstrate that ultrasonic vibration significantly enhances the feeding capacity of the casting through acoustic streaming effects and dendrite fragmentation mechanisms. Compared to castings produced without ultrasonic vibration, the aluminum piston treated with ultrasound exhibited noticeably refined grains. As the ultrasonic power increased, the vibration amplitude gradually rose, and the grain refinement effect initially strengthened and then weakened. The optimal grain refinement and the fewest defects were achieved at an ultrasonic power of 840 W.