Study of Properties of High Zn Content Aluminium Alloys for Thin Wall Deep Cavity Casting

An aluminum alloy with a high Zn content (Zn > 4%) was developed to address the casting requirements of thin-walled and deep-cavity structural components. The alloy was modified and optimized through the addition of trace rare earth elements and amorphous alloys, and it was prepared using the induction electromagnetic stirring process. These enhancements significantly improved the alloy’s strength, corrosion resistance, and casting performance. A systematic evaluation of the alloy’s mechanical and thermal properties was conducted using multi-scale simulation methods in the context of lightweight backpack radio design. The mechanical simulation results indicate that the resonant frequency of the optimized aluminum alloy component is effectively decoupled, and its impact resistance meets the 40 g sawtooth wave requirement. However, the stiffness of both the power supply module and the integrated service module requires further improvement. Thermal simulation findings show that after one hour of continuous operation at room temperature, the shell temperature remains below 67 °C. During sustained high-temperature transmission and reception, the internal device temperature, including the junction temperature of the power amplifier tube, reaches 119.5 °C. Both values remain within acceptable tolerance thresholds, fulfilling the heat dissipation and reliability requirements. Overall, the results demonstrate that this high-Zn aluminum alloy exhibits excellent comprehensive performance and is well suited for the lightweight fabrication of thin-walled and deep-cavity complex structures, thereby offering a new material solution for aerospace and advanced equipment applications.