Influence of Vibration-Assisted Dynamic Solidification on Microstructure and Mechanical Properties of Permanent Mold Cast Aluminum Alloy 2024 with Conformal Cooling

Aluminum alloy 2024 (AA2024) is widely used in the aerospace sector, where a fine, uniform, and equiaxed grain structure is crucial for achieving enhanced mechanical properties. This study examines the effect of dynamic solidification, assisted by mechanical vibrations and conformal cooling, on the microstructural evolution and mechanical properties of permanent mold-cast AA2024. Mechanical vibrations were applied during solidification in the frequency range of 15–45 Hz and acceleration of 0.5–1.5 g. Process parameters, including pouring temperature, die temperature, vibration frequency, and acceleration, were optimized using an L9 orthogonal array based on the Taguchi method. Analysis of variance (ANOVA) was performed to determine the significance of the aforementioned process parameters. In addition, the alloy’s microstructure was observed through a microscope, which revealed a transition from dendritic to non-dendritic microstructure due to dynamic solidification. The average grain size of the alloy was significantly reduced by 40.9%. Moreover, the values of hardness and Ultimate Tensile Strength (UTS) of the alloy were improved by 13.5% and 10.6%, respectively. Optimal results were obtained at a pouring temperature of 750 °C, die temperature of 150 °C, frequency of 45 Hz, and acceleration of 1.0 g. Moreover, uncertainty analysis for all three responses was also performed.