ZL105 A rocker arm shell casting was fabricated by low pressure casting. According to the structural characteristics and performance requirements for ZL105 A alloy and the casting

the optimization of ZL105 A alloy was carried out from the aspects of melt refining

alloying

casting process design and ProCAST numerical simulation

and the key points for casting process of rocker arm shell castings were analyzed. The results indicate that the comprehensive mechanical properties of ZL105 A alloy can be effectively improved by compound refining of hexachloroethane and argon rotary injection

combined with Be alloying. The low-pressure sand casting process

combined with bottom pouring+slot gating system and the method of placing cold iron on thick and large parts were adopted to obtain rocker arm shell casting with desirable internal quality

where the mechanical properties of the casting body can reach up to σ

b

≥318 MPa

σ

0. 2

≥261 MPa

δ

5

≥5.6%

respectively

and body fatigue performance

internal quality and dimension meet the designing index requirements.