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<p>The ADC12 aluminum alloy automotive air compressor housing investigated in this study is a typical high-pressure die-cast component with coupled thin- and thick-wall sections. It requires not only high dimensional accuracy but also reliable airtightness around the critical machined-hole regions. Owing to its complex internal cavity, local heavy sections, and subsequent machining holes, the original process was susceptible to gas entrapment, shrinkage porosity, cold-shut risk, and leakage after machining. In this work, an industrially produced automotive air compressor housing was investigated by combining production-defect observation, X-ray inspection, industrial computed tomography (CT), and MAGMASOFT 6.1 computer-aided engineering (CAE) simulation. The defect-formation mechanism and process optimization strategy were systematically analyzed. The numerical model considered the coupled filling, heat-transfer, and solidification behavior of the shot sleeve, runner, ingates, overflow and venting system, casting cavity, fixed die, movable die, cooling channels, and shot plunger. Four coordinated optimization measures were implemented to address the original three-ingate layout, insufficient venting, local heat accumulation, and inadequate feeding in critical hole regions. The on-site continuous production data indicated that the optimized process operated within a stable production window. After optimization, the CAE results showed a more balanced filling-temperature field and gas-discharge path, with reduced predicted air entrapment, peak trapped-air pressure, and porosity tendency. Metallographic and SEM/EDS observations further showed a finer and more uniform microstructure with fewer pore-type defects. No shrinkage cavity or porosity-related defect was observed in the representative industrial CT section. XRD detected no abnormal new phase, indicating that the improvement mainly resulted from process control rather than phase transformation. Factory quality feedback further showed that the leakage rate of the related product series decreased from a historical peak of 10.1782% to 0.9049%-1.0717%, corresponding to a reduction of approximately 89.5%-91.1% and meeting the specified leakage-control target. The Vickers hardness showed an increasing trend from 113.41 HV to 123.00 HV and was used as an auxiliary indicator of local mechanical response rather than as the sole statistical proof of process improvement. The results demonstrate that CAE-guided coordination of gating, venting, cooling, and feeding can improve the internal soundness, leakage-control performance, and production stability of complex HPDC aluminum alloy housing components.</p>

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Defect-Oriented Process Optimization of High-Pressure Die Casting for an Automotive Air Compressor Housing

  • 期刊论文

  • 发表日期：

    2026年7月18日

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  • Yusong Wei,
  • Xiangdi Liu,
  • Junyi Liu,
  • Huayong Tang,
  • Xiong Su,
  • Yu Liu,
  • Weiming Zhou,
  • Yunying Liu

摘要

The ADC12 aluminum alloy automotive air compressor housing investigated in this study is a typical high-pressure die-cast component with coupled thin- and thick-wall sections. It requires not only high dimensional accuracy but also reliable airtightness around the critical machined-hole regions. Owing to its complex internal cavity, local heavy sections, and subsequent machining holes, the original process was susceptible to gas entrapment, shrinkage porosity, cold-shut risk, and leakage after machining. In this work, an industrially produced automotive air compressor housing was investigated by combining production-defect observation, X-ray inspection, industrial computed tomography (CT), and MAGMASOFT 6.1 computer-aided engineering (CAE) simulation. The defect-formation mechanism and process optimization strategy were systematically analyzed. The numerical model considered the coupled filling, heat-transfer, and solidification behavior of the shot sleeve, runner, ingates, overflow and venting system, casting cavity, fixed die, movable die, cooling channels, and shot plunger. Four coordinated optimization measures were implemented to address the original three-ingate layout, insufficient venting, local heat accumulation, and inadequate feeding in critical hole regions. The on-site continuous production data indicated that the optimized process operated within a stable production window. After optimization, the CAE results showed a more balanced filling-temperature field and gas-discharge path, with reduced predicted air entrapment, peak trapped-air pressure, and porosity tendency. Metallographic and SEM/EDS observations further showed a finer and more uniform microstructure with fewer pore-type defects. No shrinkage cavity or porosity-related defect was observed in the representative industrial CT section. XRD detected no abnormal new phase, indicating that the improvement mainly resulted from process control rather than phase transformation. Factory quality feedback further showed that the leakage rate of the related product series decreased from a historical peak of 10.1782% to 0.9049%-1.0717%, corresponding to a reduction of approximately 89.5%-91.1% and meeting the specified leakage-control target. The Vickers hardness showed an increasing trend from 113.41 HV to 123.00 HV and was used as an auxiliary indicator of local mechanical response rather than as the sole statistical proof of process improvement. The results demonstrate that CAE-guided coordination of gating, venting, cooling, and feeding can improve the internal soundness, leakage-control performance, and production stability of complex HPDC aluminum alloy housing components.