Study on Structural Optimization and SLM 3D Printing Process of AlSi10Mg Piston
1. School of Mechanical, Electronic and Control Engineering, Beijing Jiaotong University, Beijing 100044, China
2. 52 Institute of China North Industries Group, Ningbo 315100, China
3. China FAW Group Technology Center, Changchun 130062, China
4. Marine Equipment and Technology Institute, Jiangsu University of Science and Technology, Zhenjiang 212100, China
| Abstract: | Using topology optimization and selective laser melting (SLM) 3D printing, lightweight AlSi10Mg pistons are designed and manufactured to enhance engine power output. A heat transfer/structural mechanical model is established, optimizing piston skirt, annular internal cooling oil passage, support structure, and evaluation of the printing process. Printing accuracy, microstructure, mechanical properties, and post-installation power output are analyzed. Results indicate a trapezoidal cross section, with the annular cold oil passage exhibiting superior heat resistance/load capacity. Vertex coordinates are (26.3,3), (28.3,3), (28.3,9), and (27.3,9). Volume reduced from 55359 mm3 to 46715 mm3. Pin hole and head lower end are supported, with maximum displacement at the upper end face corner of the skirt inner surface-head, 0.57 mm. Outer skirt surface displacement is 0.29 mm, while skirt upper end face displacement is minimal, 0.15 mm. Room temperature structure is primarily eutectic (α-Al+Si) with minor Al2Cu. Annealed at 300°C for 2 h, Young's modulus is 68.8 GPa, yield strength is 244.5 MPa, tensile strength is 366.6 GPa, fracture strain is 3%, Poisson's ratio is 0.31, and Vickers hardness is 1230.9 MPa. After installation, the maximum speed of the three-cylinder engine increases from 3710 RPM to 3920 RPM, and the maximum shaft horsepower increases from 100 BHP to 112 BHP. |
| Keywords: | Piston; AlSi10Mg; Structural Optimization; SLM; Mechanical Properties; Power Output |
| DOI: | 10.57237/j.mater.2024.04.001 |
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Received: 22 June 2024
Accepted: 10 July 2024
Published Online: 18 July 2024
Funding
| 1. | 国家自然科学基金 (基金号: 52371129) |
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